FLP Aloe Vera Manufacturing Process

1. Cultivation
Each aloe plant starts out as a shoot, or pup. After approximately 3 years of careful cultivation, each mature aloe vera leaf is gently removed from the plant by hand with a small incision on the bottom edge of the leaf. Once the leaf is removed, it is quickly transported for processing so that the gel remains in its freshest,purest form.

2. Cleaning & Extraction
The leaves undergo a thorough cleaning process where they’re bathed several times in cool water and given a high-pressure wash. Any remaining debris is removed, and the leaves are inspected for defects. The leaves are then filleted.

3. Stabilization
FLP’s patented gel extraction system separates the clear aloe gel from the outer leaf. The pure aloe gel is collected in stainless steel containers, and immediately goes through a patented stabilization process that protects it from oxidation, and seals in its natural potency. We own numerous patents for the stabilization of aloe vera which assures you of the highest quality products.

4 Testing
After stabilization, the gel undergoes extensive laboratory testing and analysis to ensure purity and consistency. Once the aloe gel has been tested and approved, it’s transported to FLP’s product
manufacturing plant, Aloe Vera of America, in Dallas, Texas where it’s put through a series of microbio-logical and quantitative testing.

5 Filling
Our new aloe vera bottling line fills bottles to an accurate level and is capable of running at high speeds filling as many as 300 bottles per minute, or 18,000 bottles per hour. This new filler is fully automated and state of the art. It’s design provides for an in-line, 100% inspection of each bottle after each critical step of the filling process. The operation begins with a de-palletizer, which gently slides bottles onto the conveyer. The bottom of each bottle is then printed with a lot number and is immediately inspected with a high speed digital camera. The bottle then passes through a sanitizing device, to mitigate the possiblity of physical or microbial contamination. The bottle exits this device on an enclosed conveyor and into the sanitary environment of the bottle filler.

6 Sealing
The new production line incorporates a sealing device integrated with the filling machine. The foil seals are punched from a sheet and formed into caps. The caps are sealed on the bottles immediately after they are filled and before they exit the sanitary environment of the filler. Next, the bottles are individually weighed using a high speed scale and then the bottles pass through a leak detection system to insure the integrity of the foil
seal. The bottles are then capped and passed through an xray machine to check for any foreign contaminants.

7. Packing
Each minute, 25 cases are erected by the case packing robot. The robot gently places the bottles into the case boxes, four cases (48 bottles) at a time. Then the cases are taped and weighed to ensure they have 12 bottles in each.

 8. Palletizing
Next, the bottles move to the Palletizing Robot which stacks the cases onto the pallet in a pattern that is pre-programmed. This is a big improvement for the safety of our employees who no longer have to hand-stack each drink pallet. Finally, the finished pallets move to the stretch-wrapping device and are ready for transportation into the warehouse.

 9. Shipping
AVA ships hundreds of containers every month; in fact, we are one of the largest exporters in the southern United States. These containers are sent to well over 140 countries worldwide providing people—just like you—with what we know to be the very best health products in the world.

10. Delivery
At Forever, we focus on providing our over 9.25 million Distributors worldwide with the highest quality aloe vera-based health and beauty products. We are very proud that our products have benefited millions in the US and over 140 countries around the world, and we promise to continue our pursuit of quality and excellence!