Dairy Factory Optimisation consultancy, Middle East
A 750,000 litres per day dairy manufacturer, based in the Middle East, producing UHT liquid milk, whole milk, skimmed milk and whey powders, hard pressed cheese, cream cheese processed cheese, mozzarella cheese and dairy based desserts.
The production and packing output was low compared to the nameplate theoretical capacities and quality issues and costs were mounting. The plant was processing approximately 750,000 litres of milk per day and wishing to grow rapidly to over 1,000,000 litres per day. The client needed to streamline its operation to allow for this growth without disrupting daily production.
Watson Dairy consulting undertook a full manufacturing review of this complex multi dairy products site to identify areas of improvement, change, investment and rationalisation. We reviewed the product range, packaging, processes, people, quality systems, utilities, maintenance, engineering facilities and prepared a report detailing recommendations to optimise the plant operation and maximise output with improved quality to enable the plant to reach its goal of processing over 1,000,000 litres of milk per day. We prioritise low / no cost areas for improvement which can have a significant impact on profitability. We take into account operational costs as well as efficiency and dairy yield / dairy wastage in milk and utilities and packaging.