Quality Job One

Over the decades, Quality Cheese has become a household name for legions of Canadian consumers who had savored the company’s exceptional products.

Headquartered just north of Toronto in Vaughan, Ont., the family-owned cheesemaker is renowned for its Albert’s Leap and Bella Casara brands, catering to both retail and food-service sectors, in addition to producing high-end, private-label products for leading mass merchandisers like Costco and several large supermarket chains.

Like many quintessential Canadian food industry success stories, Quality Cheese owes its good fortune to the dedication and vision of the Borgo family.

Founded by family patriarch Almerigo Borgo, the company is nowadays operated by his three male siblings—Bill, Albert, and Joe Borgo—with each contributing their unique skill sets and a shared passion to propel Quality Cheese to new heights in the Canadian dairy business.

Today employing over 100 people, the second-generation Italian-Canadian enterprise has successfully leveraged the family’s dedication and love for their culinary artistry to transform a once-modest enterprise into a globally recognized producer, distributor and retailer of Italian-style specialty cheese and cheese snack products.

The Borgo family’s roots trace back to the city of Vicenza in northeast Italy, where Almerigo Borgo grew up and laid foundation for their family’s legacy in cheese making.

Along with other family members, Almerigo was deeply involved in operating a cooperative dairy farm and cheese factory, nurturing a strong personal connection to the land and the local community.

This close-knit relationship with farming and cheese production became crucial during the tumultuous times of World War II.

As Almerigo’s eldest son Bill recalls with stories passed on from his childhood, the family faced some enormous challenges during the war years, which it ultimately overcame with remarkable resourcefulness and resilience ingrained in its hardworking ethos, leveraging its farming expertise and community support networks.

As a young man, Almerigo recognized the need to move to towns with larger milk supplies, seeing it as an avenue for greater opportunities in cheese production.

Dedicating himself to mastering the art of cheese making, he picked up many valuable insights and production techniques—until mandatory military service interrupted his pursuits.

Upon completing his military duties, and determined to explore new horizons, Almerigo made a life-changing decision to immigrate to Canada in the late 1950s.

As Bill recalls, “While many Italian immigrants made their journey to Canada by boat, my family arrived via a plane, albeit with some harrowing experiences as the aircraft almost broke down four times.

“Despite the rough arrival, my father went on to work for CN Rail, contributing significantly to construction projects in Kingston and Montreal related to the natural-gas infrastructure.”

In 1957, Almerigo, his uncle and his grandfather established their cheese-making operations in Orangeville, Ont., about an hour’s drive northwest of Toronto.

At the time, sourcing milk posed many logistical challenges, as dairies had to travel to farms to obtain their raw product.

But the industry landscape changed significantly in 1965 when leading Ontario farmers united to form the Dairy Farmers of Ontario—ensuring standardized milk prices across the province.

This pivotal development enabled Almerigo to set up a factory in Toronto’s northwest, significantly streamlining milk procurement and production processes.

With a focus on crafting fresh handmade mozzarella and ricotta, he swiftly filled the existing market void for such products, laying foundations for a remarkable journey marked by relentless pursuit of innovation.

As part of that journey, Bill’s sojourn to Europe in his youth to master cheese-making techniques enabled him to add pioneering cheeses like Borgonzola, Smoked Mozzarella, Smoked Provolone, Brie, and Camembert to Quality Cheese’s product line—thereby injecting much-needed diversity into Ontario’s cheese scene in the 1960s.

Almerigo’s dedicated efforts to grow the business were largely based around merging traditional cheese-making methods with modern techniques, before selling the original business and acquiring Quality Cheese in 1988.

By 2000, the Borgos inaugurated a cutting-edge production plant in Vaughan, commencing the production of soft-ripened cheeses. In 2016, the company commenced operations of another plant in Orangeville, with a specialized focus on Brie cheese production.

The strategic shift ushered in a period of expansive growth, marked by enhanced product diversity and quality.

With numerous opportunities presenting themselves, the company capitalized on these openings, resulting in the development of a diverse array of refined product offerings.

As one of the larger processors in Ontario, Quality Cheese uses about 160,000 litres of milk a day, producing approximately 16 tons of cheese.

Boasting two expansive processing facilities, one dedicated to Italian cheeses and the other to French varieties and some select Italian soft cheeses, the company’s operations reflect a deep-rooted commitment to excellence and specialization.

Back in 1999, the company launched a major rebranding initiative that introduced two new sub-brands, including:

• The Bella Casara range of specialty Italian cheese comprising premium-quality mozzarella, ricotta, provolone, mascarpone, and buffalo cheeses.
• The Albert’s Leap family of soft-ripened and specialty cheeses, such as brie, Camembert, washed-rind, blue cheese, goat cheese and firm cheeses, drawing inspiration from the family’s extensive global travels and experiences.

In addition, the company implemented plans to expand its repertoire and capabilities by investing in new shredding operations for production of sliced cheese products, while also installing a new production line dedicated exclusively to smoked cheeses, including various cheddar, mozzarella, and provolone varieties.

The entire process was seamlessly integrated into a highly efficient cut-and-wrap operation for high-volume production of high-quality smoked cheese products.

As vice-president of sales and marketing at Quality Cheese, Sean Nolan plays a pivotal role in shaping the company’s strategic direction and market positioning.

With keen focus on innovation and customer satisfaction, Nolan oversees a diverse range of responsibilities that contribute to the company’s success and growth trajectory, with his collaborative relationship with the Borgo brothers underscoring the company’s cohesive approach to achieving excellence in every aspect of the business.

This includes the company’s quick adaptation to the new realities of the dynamic and dynamic fast-changing retail landscape, particularly the meteoric rise of the e-commerce and online shopping segments.

Nolan says the company was quick to react to this shift by launching its own e-commerce platforms and expanding its product offering for online sales.

“E-commerce may mean you have different sizes of product you sell to that market,” Nolan notes, “whether it’s snack cheese or bulk cheese.

As Nolan points out, the company’s unwavering commitment to food safety and quality assurance is strongly validated though its SQF (Safe Quality Foods) certification, as well as formation of a dedicated internal food-safety team tasked with ensuring excellence across all areas of the business: from milk receiving to finished goods and packaging.

Moreover, the company’s minimal use of artificial ingredients or additives positions Quality Cheese products as a real health-conscious choice for Canadian consumers, Nolan contends.

As regional sales representative for Burlington, Ont.-based food packaging and processing machinery distributor Reiser Canada, Terry Rees has played a pivotal role in upgrading Quality Cheese’s packaging and processing capabilities since 2007.

A leading Canadian-based supplier of innovative equipment solutions for food manufacturers—with primary focus on processing, portioning, packaging and quality control—Reiser Canada has proven to be an invaluable partner in Quality Cheese’s quest for to redefine the landscape of cheese packaging and processing through product excellence and innovation.

As Rees reveals, “The interesting thing about Reiser Canada is that we have eight salespeople across the country, but we have 24 people in the service department.

“That’s a three-to-one ratio of service to sales,” says Rees, stressing the company’s strong focus on customer service excellence.

Adds Bill: “Our enduring reliance on the rollstock machine, procured from Reiser Canada in 2007, speaks volumes about the exceptional service and reliability we’ve experienced.

“We now operate four rollstock machines across four separate plants, highlighting their lasting value and our unwavering trust in Reiser’s products.”

As Bill relates, the collaboration between Reiser and Quality Cheese has redefined the landscape of cheese packaging and processing in Canada through a dynamic partnership focused on innovation and excellence.

At the forefront of this transformational journey is Reiser’s Repak RE 25 thermoform packaging machine that transformed Quality Cheese’s packaging processes.

“It’s very versatile,” say Bill, adding it is one of his favorite machines at the plant.

“Our extended version provides more room to load, especially for the rigid packaging and sliced products, and the added labeling system above and below the machine is invaluable.”

Lauding the machine’s versatility, Bill elaborates: “In addition to packing provolone’s and fresh mozzarella, with this machine we’re able to pack sliced cheeses, fluid products and creamier mozzarella cheeses.”

Designed to deliver optimal process efficiency and maximum product freshness, Repak RE 25 system’s exceptional versatility in handling various foils, along with a multitude of customizable features, facilitated seamless integration into Quality Cheese’s production process, becoming the cornerstone of the Vaughan plant’s operations.

Its precision in packaging Vegetal Mozzarella Creme in consumer-friendly packages, for example, makes it an invaluable asset for meeting market demands and seamless adapting to shifts in consumer preferences.

“When packaging creamy mozzarella, the product is being precisely dosed into 250-gram packages, with the flexibility to pack 500-gram packages as well,” says Bill.

“The machine’s versatility really shines with its labeling capabilities and different die-cuts for precise cutting.”

The dynamic collaboration between Quality and Reiser extends beyond packaging to encompass cutting-edge processing solutions.

These include the compact and highly efficient Holac Cheesmaxx 200 cheese-cutting machine, which handles high-speed shredding and dicing tasks with virtually unrivaled precision on the plant’s pizza topping lines.

As Rees notes, the machine’s dynamic capabilities highlight its versatility and practicality—significantly contributing to the plant’s overall operational efficiency and product quality.

“This precision not only enhances product aesthetics but also facilitates even melting and distribution during cooking, elevating the overall culinary experience,” Rees adds.

“From softer cheeses to harder varieties, it maintains its efficiency and precision, meeting the diverse needs of cheese-processing lines in the industry.”

The partnership between Reiser and Quality Cheese also extends to advanced packaging solutions like the Supervac GK501B with an AT8 shrink tank, enhancing packaging capabilities for larger cheese products.

As Bill explains, “The Supervac GK501B and AT8 machines are indispensable for packaging larger cheese wheels and blocks in shrink bags.

“Their robust design and advanced vacuum technology guarantee airtight seals, safeguarding the cheese from moisture and contaminants during storage and transit.”

Adds Reiser’s Rees: “The GK501B’s precision in vacuum levels and sealing parameters allows for customized packaging, perfectly aligning with their diverse cheese types and sizes.”

As for the AT8 automatic shrink tunnel, “It seamlessly complements the vacuum process by applying heat, tightly conforming the shrink film around the cheese,” Bill states.

“The tunnel’s adjustable settings ensure uniform shrinkage for various cheese sizes, enhancing presentation and product integrity.”

For its part, the new Vemag Cheese Shape Former plays a crucial role in Quality Cheese’s operations by producing shaped cheese snacks such as sticks, discs, and other creative shapes.

Additionally, the Shape Former has become instrumental in re-purposing cheese offcuts and scraps, according to Bill, transforming them into premium snacks or cheese blocks.

Bill says he is also highly impressed by the mesmerizing capabilities of the Seydelmann K 120 AC8 Bowl Cutter, showcasing its pivotal role in creating finely graded powdered cheese blends efficiently, precisely, and perfectly tailored to meet the stringent requirements of food-service industries.

“The Seydelmann K 120 AC8 Bowl Cutter is a marvel of engineering,” Bill enthuses. “It features a set of precision knives within a rotating bowl, meticulously chopping ingredients suspended within.

“For instance, we can introduce three distinct cheese varieties into the machine, and in a mesmerizing display of efficiency, the Bowl Cutter sizes them down to a perfectly graded texture, while seamlessly blending them.

“Not only does it handle cheese with finesse, but it also incorporates additives like anti-caking powder seamlessly into the mix,” he stresses.

“The entire process, from chopping to blending, takes merely about a minute and a half, making it ideal for food-service or industrial-scale applications.

“Beyond its mesmerizing cheese-blending prowess, the Seydelmann K 120 AC8 Bowl Cutter boasts high versatility in handling various ingredients,” he adds.

“We have frequently utilized it for creating spice blends and textured mixes, showcasing its adaptability across different product lines.”

The machine’s precise control over blending and texture consistency ensures uniformity in every batch, meeting the exacting standards of Quality Cheese’s diverse clientele.

As Bill proudly proclaims “The Seydelmann K 120 AC8 Bowl Cutter isn’t just a machine: it’s a cornerstone of our production, embodying innovation and precision to deliver top-quality products every time.”

In addition to the cutting-edge machinery, Quality Cheese also derives great benefits from its dynamic relationship with Reiser Canada in terms of impeccable after-sales service and support, according to Nolan, continuously reinforcing the company’s prominent position in the Canadian cheese manufacturing industry and setting new standards for product quality, consistency and customer satisfaction.

All in all, the proud Borgo family legacy embodied by Quality Cheese is a testament to the power of dedication, innovation, and family values in shaping a successful business venture.

From humble beginnings in Italy to pioneering cheese-making techniques in Canada, the Borgo family’s journey epitomizes resilience and a relentless pursuit of excellence through adaptation, growth and strategic partnerships.

Through collaborations with industry leaders like Reiser Canada, Quality Cheese has not only modernized its operations but also prioritized sustainability, quality assurance, and customer satisfaction, while showcasing the company’s commitment to diversification and meeting evolving consumer preferences through an expansive and diverse product portfolio ranging from traditional Italian cheeses to innovative global-inspired creations.

And as Quality Cheese continues to thrive in the Canadian food industry, it continues to stand out as a beacon of cultural diversity, innovation and unwavering quality standards to ensure that the family’s legacy will live on well into the future, while rewarding Canadian consumers with some of the finest cheese products made anywhere in the world for generations to come.