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Dairy Crest Butter Making Upgrade

Plant upgrade to increase butter making capacity at a dairy plant

Providing equipment installation, integration, automation and commissioning support to increase production capacity for a dairy manufacturing company

Plans to increase production capacity at the existing site

The company is a leading British dairy products company with four manufacturing facilities across England. It produces some of the leading brands for butter, cheese, spreads and other dairy products. The company was planning to upgrade the facility and increase its butter making capacity with a project valued at around £2.1 million.

Scope of work increased to provide additional support for plant upgrade

Malone Group was selected by the company to deliver the project to increase butter making capacity at the plant based on its considerable knowledge of the dairy sector and dairy process technologies. The company was well aware of the expertise and knowledge of our team since we had successfully delivered key projects, including multi million pound turnkey projects for the company over the last 18 years.

The scope of our work initially focused on the refurbishment of an existing finished product CIP set, as well as the design and installation of a new product CIP set at the dedicated creamery site. This project also included the reassignment of clean rooms in accordance with the utilisation study.

Recognising Malone Group’s expertise and considerable knowledge of the dairy plant, the customer extended the scope of work to encompass the areas of raw cream storage; finished cream transfer, storage and supply to a refurbished butter churn, and the field routing of the CIP. We were allocated responsibility for the partial supply, integration, commissioning and testing of the new and upgraded process equipment and control technologies. With the extended scope of work, we also provided Siemens S7 code for the replacement plant and upgraded the remainder of the plant from S5 to S7 PLC software.

Throughout the delivery of the project, we ensured that normal plant operations were maintained, with only carefully timed minor shutdowns as required. We focused on risk mitigation, employing the highest standards of site safety, anticipating potential issues and ensuring that uncompromising levels of both staff safety and food safety were maintained throughout the project.

Increasing the production capacity with minimum operational disruption

Malone Group played a key role in the expansion of the butter-making capacity at its ‘super dairy’ site. The project saw the butter production increase from 6,000 tonnes to 30,000 tonnes per annum, with minimal disruption to the existing plant operations.