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Dairy Factory Optimisation, Middle East

Process Optimisation

Dairy Factory Optimisation, Middle East

Scaling a multi-product dairy from 750,000 to 1M+ litres/day

Services Portfolio
Project Snapshot
ClientMulti-product dairy manufacturer (Middle East)
Sector / ProductsUHT milk, whole milk, skim milk, whey powders, hard-pressed cheese, cream cheese, processed cheese, mozzarella, dairy desserts
Scale750,000 → 1,000,000+ litres/day
YearCompleted
ServicesProcess Optimisation, Factory Design Review, Yield Improvement

The Challenge

The plant was processing approximately 750,000 litres of milk per day and growing rapidly toward 1,000,000 litres per day. Production and packing output ran significantly below nameplate theoretical capacity, while quality issues and operating costs were mounting.

The client needed to streamline operations to support this growth without disrupting daily production — a complex challenge given the breadth of products (UHT, multiple cheese types, powders, desserts) and the integrated nature of utilities, packaging, quality and engineering systems.

The Approach

  • Full manufacturing review across all product lines
  • Assessment of product range, packaging, processes, people, quality systems, utilities, maintenance and engineering facilities
  • Identification of areas for improvement, change, investment and rationalisation
  • Prioritisation of low/no-cost improvements with significant profitability impact
  • Analysis of operational costs alongside efficiency, yield and dairy/utilities/packaging wastage
  • Detailed recommendations report

The Outcome

A clear roadmap to enable the plant to reach its target of 1,000,000+ litres/day with improved quality, prioritising high-ROI improvements and quantifying the impact of each recommendation on yield, cost and throughput.

Services applied — click for more
Process Optimisation Factory Design Benchmarking
Facing a similar challenge? Watson Dairy Consulting provides independent process optimisation support across the dairy industry, drawing on 50 years of operational experience. Contact Watson Dairy Consulting to discuss your project.

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Note on confidentiality: Some project details are anonymised to respect client confidentiality. The technical scope, approach and outcome described accurately reflect the work undertaken. For project-specific references and credentials, please contact Watson Dairy Consulting.



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