The pre-prepared foods market is experiencing rapid growth, driven by consumer demand for quick, nutritious meals. Recognising this shift, Noble Foods—best known for its flagship brand, the happy egg co.—has partnered with Starfrost, a leading innovator in cooling technology, to launch a new range of value-added, ready-to-cook omelettes.

Central to this collaboration are two of Starfrost’s state-of-the-art Helix Spiral Freezers, which are enabling Noble Foods to launch a new production line efficiently while maintaining the highest standards of product quality and consistency.

We spoke with Pete Robertson, Project and Engineering Manager at Noble Foods, to discuss the company’s move into convenience foods and the role Starfrost’s technology is playing in their expansion.

Noble Foods is known for its popular brand, the happy egg co. Can you tell us about your new venture and why you decided to move into the value-added convenience sector?

“We’ve always taken pride in delivering high-quality, egg products, and we’re seeing increasing demand for more convenient, nutritious and protein-rich options that suit today’s fast-paced lifestyles. Moving into the pre-prepared food space was a natural progression. Here at our new innovation and manufacturing site, our first products off the production line are frozen omelettes by the happy egg co., which is part of our new value-added pipeline.”

What led you to choose Starfrost’s Helix Spiral Freezer, and how did you select the right solution?

“We hadn’t used automated freezing or chilling systems before, so we wanted to pursue the best options for our ambition. We knew we needed a system that would give us flexibility, reliability and efficiency. We found Starfrost to be a trusted name in the industry. Their equipment stood out for its durability, ease of use and the company’s commitment to long-term relationships and aftercare. That was crucial for us. The Helix Spiral Freezer ticked all the boxes.”

You explored liquid nitrogen freezing—why did you ultimately opt for mechanical freezing?

“We considered liquid nitrogen initially, but the costs and supply logistics made it less viable. Cryogenic freezing comes with volatile pricing and complex transport considerations, whereas mechanical freezing offered more stability and lower long-term costs. After in-depth discussions with Starfrost, we were confident their mechanical freezing systems could achieve the same high-quality results with greater consistency.”

How has the spiral freezer benefited you in terms of consistency and production scalability?

“The biggest win has been consistency. The freezing process is extremely reliable, which ensures our product quality remains high. From an engineering standpoint, the system is intuitive and straightforward to operate, and it performs well under different production conditions. It’s also versatile—we can seamlessly switch between products or recipes, which gives us the flexibility we need as our added-value businesses grows.”

What’s next for Noble Foods and the happy egg co. brand?

“This partnership with Starfrost is just the beginning. As our business grows, we’ll need equipment that evolves with us. Starfrost’s freezer systems provide that scalability. The Helix Spiral Freezer is future-proof—designed to handle greater capacity and accommodate alternative products as production ramps up. We’re excited for what the future holds, knowing we have Starfrost’s ongoing support.”

Future-Proof Freezing

Starfrost’s Helix Spiral Freezers provide Noble Foods with the capacity, consistency, and flexibility required to scale and diversify, enabling the food manufacturer to meet growing demand—efficiently and reliably.

The UK’s leading material handling training provider, Mentor Training, is exhibiting at this year’s IMHX event, showcasing a brand new innovative training solution that benefit learners and businesses alike.

 

With the UK witnessing around 1,300 serious injuries per year from accidents involving forklift trucks, Mentor emphasise that those working on and around workplace transport absolutely must understand the risks involved to be able to keep themselves and others safe.

 

Blended learning courses, which combine in-person training with online theoretical elements, were developed to overcome barriers to vital training. Mentor is committed to delivering industry-leading innovation, something the company aims to showcase at the upcoming event in September. Returning to the NEC, Mentor will place a strong focus on its blended learning solutions, which combine hands-on, in-person training with flexible online theory modules.

 

Adam Smith, Mentor’s Commercial Director, explains the key benefits to this training format, “Our new blended courses offer heightened convenience on multiple levels. These courses allow delegates to cut down on face-to-face training hours, using flexible e-learning modules that can be completed at their own pace, where and when they wish, around their other commitments. Not only this, but they also provide cost savings by utilising less instructor-led training days and reducing disruption to operations, as well as having the ability to be directly integrated into a business’ own learner management system.”

 

Mentor are adding to their already established blended learning course catalogue. Adam provides the details, “We’re pleased to announce the expansion of our blended learning offerings. Following successful trials, Reach Trucks and Pivot Steers will now be included in our available truck types, offering customers even more opportunities to benefit from the convenience and flexibility of blended training. These additions build on the existing Counterbalance course already in place. We look forward to sharing further details at IMHX.”

 

The event will provide the opportunity to discover innovative training solutions like this from hundreds of suppliers, and so much more. Visitors will be able to immerse themselves in augmented reality in the Future Zone, and learn something new by attending the Logistics Conference, part of which is a live mock trial centred around a forklift accident. Taking place on Wednesday 10^th September, this session is sure to provide insight into the importance of forklift safety and the consequences of accidents.

 

Adam shares his excitement for the event, “We’re thrilled to be back exhibiting at IMHX. It’s an opportunity for those attending to see the latest innovations within the industry and speak with thousands of like-minded professionals across the three days. Pay us a visit on stand UK11 for a showcase of our latest training solutions and our newest blended learning courses.”

 

IMHX 2025 takes place 9^th-11^th September at the National Exhibition Centre in Birmingham. To register for your free pass to the exhibition, click here. Or if you can’t make it, please contact Mentor here to enquire about blended learning for your business.

We present a brand-new product range designed to connect with UK consumers: a selection of best sellers offering all the flavour and craftsmanship of the Mediterranean—now under the Costa Brava Mediterranean Foods quality seal.

We’re committed to authentic recipes, traditional flavours, and practical formats that ensure a distinctive experience both from the shelf and in professional kitchens.

 

Discover our best sellers:

• Pork cutlets: Our pork cutlets are tender, juicy slices of pork loin — one of the finest cuts for texture and flavour. Each piece is carefully coated in a high-quality, golden gluten-free breadcrumb, that provides the perfect balance of crispiness and succulence.

The cutlets are pre-fried and frozen using the IQF (Individually Quick Frozen) method, which guarantees excellent product separation, facilitates handling, and ensures optimal cost control. This advanced freezing technique preserves the product’s integrity and texture, even after extended storage.

Quick and easy to prepare straight from the freezer, they are ready in just 4 minutes using a fryer, oven or air-fryer. This makes them a practical, versatile solution especially for professionals seeking premium quality with minimal prep time.

We offer two delicious varieties:

• Classic Pork Cutlet: A traditional favourite — juicy, tender and coated in a light, crispy gluten-free breading. Its classic oval shape makes it ideal for plated dishes, meal kits or gastro bars. A reliable and tasty option to enjoy anytime.
• Pork Cutlet “Mediterranean” (Chorizo Flavour): A unique twist made with paprika, offering a bold, exquisite flavour profile while maintaining the same crispy coating. Its rounded shape is perfect for sandwiches, gourmet burgers and contemporary foodservice formats.

Prepared with care and crafted for quality, convenience and consistency, these cutlets are a standout choice for operators seeking innovation without compromising tradition. Designed to adapt to modern menus while staying true to its Mediterranean roots.

 

• Pork loins: Our pork loins are one of the most premium, leanest and most versatile cuts of the pig. Naturally tender and full of flavour, they are ideal for grilling, roasting, or pan-frying — perfect for both quick meals and high-end prepared dishes.

We offer a wide range of pork loins, either plain or marinated, and prepared with carefully selected Mediterranean spices, all designed to deliver consistent flavour, convenience and quality:

• Bacon medallions: Lean, round-cut slices from the loin, offering a lighter alternative to traditional bacon — all the flavour with less fat. Ideal for breakfast menus or sandwiches.
• Brined loin: A juicy, tender cut that’s lightly brined to enhance its texture and add a subtle savoury touch. Perfect for roasting or slicing into fillets.
• Paprika loin: Marinated in sweet Spanish red paprika, this variety offers a warm, smoky flavour and vibrant colour. An excellent choice for Mediterranean-inspired recipes.
• Garlic loin: Infused with natural garlic and herbs, this loin delivers an intense aroma and rich taste. Ideal for grilling or oven-cooking.

All varieties are available as whole pieces or sliced, depending on the needs of each channel. In addition, they are gluten-free, quick to prepare, and offer maximum ease for both professionals and retailers. Whether it is used for ready meals, retail trays or foodservice menus, our pork loin range delivers quality and a Mediterranean spirit in every bite.

• Spanish Gourmet croquettes: An iconic classic of Spanish tapas culture, croquettes are delicious bite-sized treats made with a creamy béchamel base, traditionally combined with premium-quality ingredients. The mixture is coated in breadcrumbs, and fried until golden and crispy on the outside, with a soft velvety centre.

At Costa Brava Mediterranean Foods, we craft our croquettes using authentic Spanish recipes and natural ingredients, preserving their traditional character. They are easy to prepare—either fried, airfried or oven-baked—and ideal for sharing, making them an excellent choice as a starter, part of a tapas selection, or for casual dining.

 

We offer our clients a range of distinctive flavours, including Iberian ham, chicken, chorizo,

and roast meat. All varieties are available in flow packs for Foodservice and Retail up to 1kg. Our gourmet croquettes deliver a high-quality, flavourful experience that brings the essence of Spain to every dish.

 

With this range, we help bring the best of the Mediterranean to British kitchens, offering innovative, flavourful solutions that meet the expectations of today’s consumer.
Want to learn more? Contact our sales team at sales@costabravafoods.com to discover how we can help you make a real difference in your market.

Oakland International, a leading specialist in distress load management, is calling for immediate industry and government action to address the crisis of distress loads and clandestine infiltration of commercial vehicles, a threat that endangers food safety, driver welfare, and the integrity of the UK’s supply chain.

 

Launching their comprehensive new report on Distress Loads and Clandestine Infiltration of Commercial Vehicles, developed in partnership with market analysis company Analytiqa, Oakland International exposes the urgent need for coordinated action, particularly across the food supply chain. The report draws on extensive market research and operational data and highlights a lack of clarity and understanding of ‘best practice’ when it comes to the responsibility, or accountability, for distress load stock.

 

Contributions and insights from the Road Haulage Association (RHA) and the British International Freight Association (BIFA), reflect the perspectives of leading industry bodies and underscores the breadth of collaboration needed to address the urgent challenges facing the UK’s supply chain. It also highlights the vital roles played by charities, FareShare and City Harvest London, for their work in food redistribution and tackling food insecurity across the UK.

 

RHA Senior Public Affairs Lead Ashton Cull commented: “The Independent Chief Inspector of Borders and Immigration (ICIBI) said in their recent report “the threat of clandestine entry at the juxtaposed ports remains high and is unrelenting”, findings echoed in this report. That means everyone based at or using these ports has their part to play to keep the border secure.

 

“However, failings within Border Force and the Clandestine Entrant Civil Penalty Scheme identified by the ICIBI mean that all the responsibility and liability is being unfairly shifted onto drivers and businesses who have taken all possible steps to secure their vehicles from clandestine entrants. That’s why we recently wrote to the Home Secretary to call for reform of this Scheme.

 

“We repeat our call for further and urgent investment in training and technology at our borders to help keep loads secure. We want to see a fair system in place that protects drivers, goods and businesses as well as our borders. We look forward to seeing greater urgency on this issue.”

 

Oakland International Co-Founder Dean Attwell said: “The rise in clandestine infiltration is not just a statistic, it’s a ticking time bomb for food safety, driver security, and public health.

 

“Every compromised load puts the public at risk and costs the industry millions per year. We need urgent, coordinated action across the supply chain to implement robust security protocols, improve traceability, and ensure accountability at every stage.”

 

Figures from the report show a significant month-on-month increase in cases of clandestine infiltration, where migrants enter lorry trailers, putting the safety of food products and the integrity of the supply chain at significant risk. The financial and operational impact is significant, with the industry experiencing substantial losses each year as a result of spoiled loads being discarded due to infiltration and contamination.

 

Key data points highlighted by the report include:

 

• In first nine months of 2024, almost 100 people per month were detected infiltrating trucks entering the UK.
• The number of incidents in the first nine months of 2024 was higher than the equivalent periods of 2022 and 2023, up 12.8% and 60.6% respectively.
• In 2023, on average, three people were detected per instance, the highest number since 2020.
• The actual number of incidents and people detected is likely to be significantly higher, as Border Force do not record the number of vehicle checks that require no further action, so it is not possible to track how many vehicle checks are undertaken or what share of vehicles these account for.
• The value of stock lost due to an infiltrated load can be in the low £’000s to several tens of £’000s. The consequential loss of revenue can be many multiples of this.
• “There are a range of claim sizes. General foodstuffs could be £20k – £30k per trailer, chocolate brands could be £70-£80k per trailer.” Managing Director – Loss Prevention UK Insurance Industry.

 

Oakland International’s Distress Load Management (DLM) service has significantly expanded its capacity to address a growing number of clandestine infiltration cases, marking a substantial increase compared to previous years. However, as highlighted in recent reports, the actual scale of the issue is likely much greater, since many incidents remain unreported or are not formally managed.

 

Added Dean: “We are witnessing a perfect storm, desperate individuals risking their lives to cross borders, criminals exploiting vulnerabilities in vehicle security, and a food industry struggling to maintain safety and compliance.

 

“The current system is failing to protect both people and products. The Food Standards Agency must step up, and the entire industry must unite to close security gaps and safeguard our food supply.”

 

The new report, available today, details how the risks extend beyond financial loss and how contaminated loads can threaten public health and lead to mass food waste. Oakland International’s DLM service, which is BRCGS accredited and EHO approved, typically recovers over 85% of product from distress loads, with non-conforming stock safely quarantined and disposed of in line with strict procedures.

 

The report calls on all stakeholders, hauliers, retailers, regulators, and policymakers, to prioritise investment in security measures, driver training, and rapid response protocols. Oakland International stands ready to support the sector with its proven expertise in distress load management and urges greater transparency and accountability to restore confidence in the UK’s vital supply chain.

 

About Oakland International: Oakland International is a Certified B Corporation multi-temperature supply chain specialist, and a leader in direct to consumer, case consolidation, contract packing, storage and distribution, food tempering and brand development support for all types of food, operating 24/7 servicing diverse markets across the UK and Ireland, and recognised as a leader in distress load management and supply chain security.