At Hiperbaric, we know that High Pressure Processing (HPP) technology has become a key driver of innovation in the food industry. More and more companies are choosing HPP tolling (or contract manufacturing) services as a smart and cost-effective way to bring safer, fresher, and longer-lasting products to market without having to invest in their own equipment.
In this context, APA Processing, based in Barcelona, has positioned itself as the leading HPP tolling provider in Southern Europe. Since 2013, the company has processed more than 50 million units annually across a wide range of categories, including juices, plant-based beverages, ready-to-eat meals, baby food, meat, and seafood. APA stands out for its combination of industrial robustness, agility, flexibility, and a 360° service approach that includes technical validation, real-time quality control, labeling, packing, and logistics.
We spoke with Gonzalo Guarch, General Manager of APA Processing, to hear his insights on how the tolling business is evolving and the challenges ahead.
How has demand for HPP tolling services evolved in recent years?
Just a few years ago, HPP was considered a niche technology. Today, it’s seen as a strategic lever for innovation. Both startups and established brands are turning to tolling as the fastest way to scale clean-label, additive-free products with longer shelf life. The strongest growth has come from juices and functional beverages, ready-to-eat meals, plant-based alternatives, meat products, and seafood.
What is the biggest technical challenge for the tolling industry today?
The main challenge is gaining speed without losing control. The HPP chamber is just one step in the chain; reception, traceability, labeling, packing, and preparation add complexity. At APA Processing, we focus on optimizing pre- and post-HPP workflows, expanding value-added services so that products can leave our facility fully finished and ready for distribution — saving time, cost, and handling.
What are the key factors behind success in HPP tolling?
Four pillars define success:
- Reliability – guaranteeing consistency, traceability, and zero surprises.
- Flexibility – adapting to different volumes, formats, and customer requirements.
- Speed – delivering most batches within 24 hours.
- Technical know-how – over a decade of dedicated HPP expertise, supporting clients through validation, optimization, and logistics.
What are customers’ main concerns when approaching HPP tolling for the first time?
The first questions are usually: Will my product work with HPP? Is my packaging compatible? What shelf life should I expect? Our role is to bring clarity and confidence through real validation trials, helping clients make informed technical and commercial decisions.
How do you handle logistics and added services?
Logistics doesn’t stop at the HPP chamber. We coordinate product reception, quality checks, secondary packaging, labeling, and mixed-order preparation. The goal is to have products leave our facility ready to go directly to retailers or distributors, cutting down on transport, lead times, and costs.
What value-added services do you offer beyond HPP processing?
HPP is not an isolated step; it’s part of a broader solution. At APA, we provide services like secondary packaging, packing and order preparation, labeling for campaigns or promotions, and logistics coordination. Our R&D and quality team also supports validation, shelf-life studies, and packaging compatibility. The aim: to reduce complexity and time-to-market for our clients.
What does the onboarding process look like for a new client?
Onboarding is where we build trust. We start with a technical screening of product formulation, pH, water activity, packaging compatibility, and expected shelf life. If necessary, we conduct large-scale testing and microbiological validations.
Once approved, we define formats, traceability protocols, service levels, and move on to live production. For clients with limited in-house expertise, this phase is crucial — because we provide not just capacity, but technical reassurance and guidance.
What are the most common misconceptions about HPP?
One misconception is that HPP can be applied to any product in any packaging without testing. In reality, product formulation, packaging material, and microbiological load all play a role. Another misunderstanding is seeing HPP as a silver bullet for food safety. It’s powerful but requires validation and a maintained cold chain. That’s why technical validation is essential before scaling.
How important is customer feedback and long-term partnerships?
We don’t see ourselves as just a service provider but as an operational partner. Many of our service improvements — from more flexible logistics windows to value-added services like labeling and packing — came directly from customer feedback. Long-term relationships allow us to anticipate needs, improve continuously, and align completely with our clients’ supply chains.
HPP tolling has evolved from an alternative option to the fastest and safest way to scale innovation in the food industry. With its focus on reliability, flexibility, and partnership, APA Processing is proving why it is the benchmark in HPP tolling in Europe. If you want to know more, don’t miss our HPP Innovation Week session:
