With JBT Marel’s freezer solution, Costa Lavos takes its frozen bread operation to the next level
From manual operation to a modern industry, Costa Lavos embraces automation and connectivity to grow with efficiency and quality.
Family tradition with a vision for the future
Costa Lavos carries in its history the entrepreneurial spirit of a family that lives and breathes baking. Founded in 1989 in the eastern part of São Paulo, the company emerged from the work of previous generations who had run neighborhood bakeries. Over time, this tradition was transformed into an industrial operation that never lost sight of the essence of well-crafted bread.
“In our family, we like to say that flour runs in our blood. We grew up inside bakeries and turned that knowledge into an industry,” says Aline Cheves, President of Costa Lavos. “But we have always made a point of respecting the traditional process, especially in the production of French bread.”
This solid foundation, combined with a constant drive for improvement, led the company to seek solutions that would allow it to grow with quality. Today, with more than 15,000 m² of built area, two high-capacity production lines, and the ability to process 10 tons per hour, Costa Lavos is a national reference in the frozen bread supply market.
Modernization as a response to expansion
Costa Lavos’ industrial transformation began in the early 1990s, when partners Valtemir Cheves and Jaime Shervis decided to move away from the traditional bakery model to establish an industry focused on bread production.
The operation, which began by delivering baked bread to retail, evolved with growing demand and started supplying fresh bread to large-scale industrial kitchens. In the 2000s, the company entered a new phase of expansion, enlarging its manufacturing facilities and starting to produce frozen bread and dough—a segment consolidated in 2005 with Costa Lavos’ definitive entry into frozen bakery products.
The modernization of the plant accelerated in 2014 with the opening of the first branch and the adoption of semi-automated equipment that replaced fully manual processes. “We were exactly what people picture as an artisanal bakery—rolling pin, workbench, hands in the dough. But we realized that to grow, we needed a technological boost,” recalls Aline.
In 2019, this movement intensified with JBT Marel’s entry as a strategic partner and the acquisition of the first spiral freezer. This decision marked the beginning of a new era for Costa Lavos—the definitive transition from artisanal production to large-scale operations.
“Scalability without reliable equipment is almost impossible. The Frigoscandia GYRoCOMPACT freezing system gave us the robustness and stability to make this leap safely,” says partner Jaime Shervis.
Efficiency ensured at every stage
With freezing taking a central role in the production line, the choice of equipment was decisive for Costa Lavos’ performance. “If the freezer didn’t have the efficiency it does, we wouldn’t be performing at the level we are today,” Jaime emphasizes.
The chosen equipment was the Frigoscandia GYRoCOMPACT® M7 spiral freezer, with a freezing capacity of 5,616 kg/h, equivalent to 72,000 units of 78 g per hour. Installed at the end of 2019, it went into operation at the beginning of 2020.
The performance of the first GYRoCOMPACT™ motivated the acquisition of a second spiral freezer, delivered in 2024 and scheduled to begin operation in the first half of 2025. The new line represents a significant step in expanding the company’s production capacity.
Beyond the technology itself, JBT Marel’s technical support also proved essential. “We had the privilege of working with an extremely committed team. From the delivery of the first equipment to the ProCare service contract, everything was handled with great competence and close collaboration,” highlights Jaime.
Digitalization with an operational focus
Costa Lavos was also one of the first companies in the sector to adopt the OmniBlu™ platform, JBT Marel’s intelligent solution for real-time equipment monitoring and management.
“OmniBlu was a perfect fit. It identifies operational issues and helps us anticipate problems. That makes all the difference in getting the best performance from our assets,” says Jaime. The tool has been used together with the company’s management team and is already showing results in efficiency and preventive maintenance.
A long-term partnership
The relationship with JBT Marel is the result of a process built over time, now reflected in mutual trust and long-term projects. “It took more than eight years to complete the first purchase. Since then, the relationship has only grown stronger,” Jaime shares.
For Aline, this partnership was decisive in changing the company’s mindset. “In the beginning, we were a little afraid of growing. But technology and the right partners showed us that it was indeed possible to maintain our essence while gaining scale.”
Ready for the next challenges
With a modern structure, efficient processes, and an engaged team, Costa Lavos is already envisioning new horizons. “We’re designing projects for multiple production lines. And with the robustness of the equipment we have, we can think about serving other states and expanding our reach with confidence,” concludes Jaime.
About Costa Lavos
With over three decades of experience, Costa Lavos is a family-owned company that stands out for combining tradition, quality, and innovation in the bakery sector. Based in São Paulo, it operates nationwide, supplying frozen bread to a wide range of channels—from small retailers to large distributors, including supermarkets, grocery stores, convenience stores, and industrial kitchens.
The company’s pillars are product excellence, respect for its roots, and continuous investment in technology and efficiency. This blend of legacy and modernity has been key to positioning Costa Lavos as a reference in Brazil’s frozen bakery market.
