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Aleva’s New Investment
Aleva’s New Investment – Increased Capacity and Greater Production Flexibility
Thanks to its commitment to continuous improvement and long-term development, Aleva has enhanced its production capacities through the acquisition of new equipment, modernizing the packaging of its traditional products while creating opportunities for the development of new product lines tailored to contemporary consumer needs.
Founded in 1947, Aleva, based in Novi Kneževac, is today one of the most recognizable producers of ground red paprika in the region, as well as a manufacturer of products developed according to recipes created by the Aleva team. While the company’s reputation was built on the quality of its ground paprika, Aleva has expanded its portfolio over the decades to meet evolving consumer demands. Through continuous investments in innovation and equipment, and by keeping pace with technological advancements, the company has established itself as a reliable partner in the food industry, with a strong focus on product quality and safety, dependable supply, and portfolio development.
Ground paprika remains at the heart of Aleva’s production. The procurement and processing (drying) of paprika is a seasonal activity linked to harvesting and takes place between September and November. However, production operations continue throughout the year. In addition to sourcing, drying, grinding, and packaging paprika, Aleva manufactures a wide range of products, including universal seasonings, seasoning blends, meal enhancers, soups, whipped toppings, puddings, ice cream mixes, Quik instant products, and other food products.
Alongside preserving traditional production principles, the company continuously invests in modernization and the development of new products and packaging solutions.
To support planned production volumes, approximately 100 employees work at Aleva’s production facility in Novi Kneževac, with additional seasonal workers engaged during peak periods.
In a conversation with Aleva’s Director, Željko Ciganović, we learned that modernization remains a key strategic priority for the company. This commitment is reflected in the recent investment in a state-of-the-art vertical form-fill-seal packaging line operating in an automatic cyclic mode. According to Mr. Ciganović, the line is designed for packaging products ranging from 50 g to 1,000 g.
“While we have been nurturing traditional production methods since 1947, we continuously adapt to market demands through the development of new products and the introduction of modern packaging formats such as doypacks,” said Mr. Ciganović.
According to Production Manager Kinga Piliši Sirovica, the new packaging line supports various pouch formats, including pillow packs and doypacks, as well as multi-component products. The line is equipped with a screw elevator for precise dosing of powdered materials, a pneumatic conveyor that preserves the structure of granulated products, a 10-head multihead weigher, an in-line checkweigher for net weight control, and a metal detector, ensuring high standards of quality and product safety.
A New Production Platform for Multiple Product Categories
One of the key advantages of the new line is its flexibility, both in terms of products and packaging formats and materials. This modernization enables efficient packaging across different product categories while allowing rapid adaptation to market requirements. Automation has increased production speed and reduced the need for manual operations. Particularly important is the capability to package larger formats of 500 g and 1,000 g, intended for the HoReCa segment and specific customers, including private label and industrial partners.
Maintenance Manager Bogdan Benić emphasized that automation has significantly improved the overall production process. Increased speed and continuity of operations have boosted capacity, while downtime has been minimized thanks to system reliability and reduced manual intervention. Precise dosing and weight control systems contribute to lower raw material losses, while optimized package formation ensures more efficient use of packaging materials. These improvements result in both operational savings and better process control.
“Net weight verification and metal detection of every product on this line provide an additional level of safety and ensure compliance with regulatory requirements. The metal detector is capable of performing inspections throughout the entire production process, and the type of packaging material, including composite materials, does not affect detection efficiency. This significantly facilitates operations and provides an additional safeguard against physical contamination hazards,” explained Dr. Natali Mićović, Quality Assurance and Regulatory Affairs Manager.
Aleva continuously improves its packaging formats and packaging material management practices.
The new line serves as a versatile platform for multiple product categories. It can package powdered and granulated products, both savory and sweet, with the possibility of adding components such as pasta or freeze-dried fruit. In accordance with hygiene and food safety management standards and the HACCP system, particular attention is given to sanitation through regular equipment cleaning based on established procedures after production runs, ensuring readiness for subsequent product categories.
In parallel with improving production performance, the company is further developing its packaging formats and material management practices. Aleva offers several packaging types, including flat sachets, pillow packs, and, more recently, doypacks, available in various sizes ranging from small and medium formats to larger packages intended for professional and industrial use.
Responsibility First
When it comes to material management, production processes are focused on optimizing packaging material consumption and ensuring proper waste separation and disposal in accordance with packaging legislation and applicable standards. The company also implements careful production planning to reduce food loss and waste and continuously applies systematic measures to achieve its sustainability goals in this area.
Aleva’s future plans are development-oriented, while naturally depending on market conditions. In the coming years, the company intends to continue modernizing production and developing innovative packaging solutions while preserving the quality, product safety, and tradition that make the Aleva brand recognizable. Alongside technological advancement, a key focus is reducing costs and increasing energy independence, primarily through investments in solar panels. In this way, Aleva continues its transformation toward a more efficient, technologically advanced, and sustainable business model.
Source: Ambipak