How a Renowned Tortilla Producer Transformed Their Food Safety Program

Fiesta Tortillas moved their food safety and QC programs to a digital platform after forty years of paper – now they’re saving time and stress in both everyday operations and annual audit prep.

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The Client

Located in Austin, Texas, Fiesta Tortillas is a well-known manufacturer of tortillas, chips, and other products.

Since 1984, Fiesta Tortillas has had a simple mission: produce five-ingredient flour tortillas without additives or preservatives. Founder Jaime Picos and his family have delivered on this promise every day for the past forty years, now producing up to 2 million corn tortillas and 500,000 flour tortillas daily.

Sector
Tortillas, chips

Headquarters
Austin, Texas

Audit Type
GMP

Facility Size
35,000 square feet

Provision Digital Food Safety Fiesta Tortillas-min

40 Years of Paper: Time for a Change

Years of success and growth meant that data demands were bigger than ever at Fiesta; keeping up with paper records was becoming a struggle.

    • Nonconformance detection was slow due to inefficient hardcopies and mountains of paper
    • Tracing product manually for customer requests and certification compliance was time-consuming and frustrating
  • Paper-based data was prone to inaccuracies and tedious to compile and strained operating decisions

An Easy Choice and Easier Transition

Fiesta found an ally in their fight for efficiency – Provision – and adopting the platform was smooth and simple.

  • Comprehensive Spanish Support

    Provision’s partnership with Grupo Delcen offered Fiesta access to fully Spanish-language resources for software configuration and user training

  • Ease of Use
    Non-technical operators meant that the solution Fiesta chose would have to be straightforward and easy to learn
  • Customization is Key
    After 40 years of operation, Fiesta had very unique, highly-customized forms and procedures; an out-of-the-box solution wouldn’t work, whereas Provision could satisfy their need for flexibility
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"
When everything was on paper, we faced a lot of difficulties just because everything took so much time. Tracing products took forever, and we’d even find missing information that our staff hadn’t captured.
"
Elva Casarez
Food Safety & Quality Manager, Fiesta Tortillas

Improving on Excellence

How Fiesta leveraged their new digital toolbox to make their successful food safety and quality programs even better.

  • 1.

Non-Conformances in Real Time
  • Smart rules flag outlier data automatically, offering instant clarity for operators
  • Deviations can be quickly escalated and sent to management for corrective action, preventing a cascade of issues that could lead to recalls
  • Form submissions instantly update custom reports, enabling continuous monitoring of trends to better prevent recurring issues 
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"
We can use time more effectively now that we have Provision – the information is available for review as soon as it’s finished, and anyone with access to Provision can see it.
"
Zuleidy Moreno Serrano
Quality Technician, Fiesta Tortillas

  • 2.

Seamless Recordkeeping for Smooth Audits
  • Automatic task reminders ensure records are completed without nagging

  • Customizable reports summarize form submissions and enable streamlined verification and review

  • Records automatically link in an easily traceable sequence, simplifying mock recalls
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"
Audits are much easier now – we’re always prepared and don’t have to search for papers or fear that it’s not well done.
"
Zuleidy Moreno Serrano
Quality Technician, Fiesta Tortillas

  • 3.

Clear, Continuous Guidance Helps Develop Food Safety Culture
  • Attaching guidance documents and SOPs puts help at users’ fingertips no matter where they are in the facility
  • Live translation eliminates communication errors and operator frustration
  • Messaging within records brings questions together with context for a clear, intuitive experience
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"
Using Provision has really helped our operations, from capturing information to obtaining reports. It’s much quicker and easier to find specific information or conduct analysis, which especially helps with decision-making.
"
Elva Casarez
Food Safety & Quality Manager, Fiesta Tortillas

Here’s to Another Forty Years

Moving their paperwork to the digital age has reinvigorated Fiesta’s readiness to continue their multi-generational operations.

Bringing Provision into their facility has led to massive improvements for the Fiesta Tortillas team. Not only have they saved time and stress in daily operations, but the enhanced accessibility of their data has made working with their stakeholders and customers easier. Backed with real-time monitoring, management can rest assured that their decisions are fully informed and processes are streamlined. The future looks bright at Fiesta Tortillas as another generation of the family steps up to the helm.

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"
I would definitely recommend using   Provision.
"
Elva Casarez
Food Safety & Quality Manager, Fiesta Tortillas

  • 20%

    Time saved on data entry

  • 40%

    Time saved on team management

  • 40%

    Time saved on record review and verification

  • 75%

    Time saved on audit preparation