MORWELL
MANUFACTURING
PLANT
PRESENTED BY
HOWARD VELLA
(MANUFACTURING MANAGER)
Growing sociability and wellbeing in our world
Agenda
• The story so far
• Our product range
• Some statistics
• Future Opportunities
2
Morwell Site History
• Conception
August
1996
• Board approval
November
1996
• Construction started at Morwell
January
1997
• Production ex Murray Bridge
• National Foods acquire DF
September
November
1997
2008
• NF acquired by KIRIN Holdings
December
2009
• Project Rainbow Announced
June
2010
3
Aerial View
New Engineering W’shop
4
Current Range of Products
5
Products Still Under Transition
6
Yoghurt Manufacture
• Milk
• Homogenisation
• Pasteurisation
High quality with low bacteriological levels
•
•
•
•
•
To 41°C for inoculation with culture
Cooling
Incubation
Cooling
Filling /packing
Cold room
Prevents creaming, and distributes fat
At 91°C for 5 minutes, improves the milk for the
addition of culture, and ensures the end product’s
consistency is thick and creamy
Reduces the risk of whey separation
8 to 10 hours
To stop the incubation process
Into pots of various sizes, fruit added if required
Temperature brought down to 4°C before
transportation to depot
7
Site Numbers
• Factory Size (approx.)
•
•
•
•
•
12000 sq. m
Employees
162 (plus casuals)
Raw Materials Storage
435,000 litres
Stock Keeping Units (SKU’s) >100, over 21 bases
Production Lines
11
Production Volume
2010 - 53,000 Tonne
2012 - 76,000 Tonne
• Processing capacity
91,000 Tonne (53,000T pre Rainbow)
• Product Range
• Yoghurt – stirred and set
• Dairy desserts (custardd & Fruiche)
• Sour cream
8
Site Capability
Pre Rainbow
Post Rainbow
- Yogurt
44,000
78,700
- Desserts
7,800
7,800
- Sour
1,200
4,500
Total
53,000
91,000
nil
1
- FFS
13.4 (4 lines)
16.8 (4 lines)
- Pre Form Cup
3.9 (4 lines)
8.0 (5 lines)
- Tubes
3.2 (1 line)
3.2 (1 line)
- Pallecon Filler
.16 (1 line)
Processing – annual tonnes
Pilot Plant
Filling – million cups / week
.29 (1 line )
Total
20.7
28.3
Inbound Warehousing
1,678
2,435
Cooling Cells
96
125
Warm/Hot Room
40
130
300 pallets
300 pallets
Cold Room
9
Processing Plant
• Base
o Stirred Yogurt
o Natural Set Yogurt
o Fromage Frais
o Custard
o Sour Cream
• Processing Plant Stats
o 2 Pasteurisers
o 17 Maturation Tanks
o 26 PFS Tanks
o Max Processing Capacity
is 91 million kgs per
annum
10
Filling Line
Fruit Dosing
Tecma Pak
Case Packer
New Arcil
Filler
New Ermi
Filler
11
Automated Pallet Movement
12
Packaging Warehouse
13
Rainbow & Morwell 2025
• Rainbow
o Strategic intention of removing excess capacity in Dairy industry
o Create centre of dairy foods excellence @ Morwell
o Support capacity / growth and innovation to 2014/15
o Introduction of shelf ready packaging
• Morwell Future – 2025
o Planning in progress to review Morwell foot print requirements;
o Normal Growth
o Repatriation of 3rd party manufacture – Pouches & Le Rice
o Consider emerging trends in categories and capabilities
o Desserts, Pot set
14
Morwell Projects
Project
Timing
Progress
Reformulation of Light & Original Yoplait and Yoplus and
introduction of sleeved 4 pack
February
2012
Complete
Replacement of Hassia Tube line with Arranow filling Line
April
2012
In Progress
Construction of humidity and temperature controlled shelf life
Incubation Room
January
2012
In progress
Development of Dairy Dessert product lines in square tub
format and increase in Pallecon filling capacity
June
2012
In progress
Modification of downstream packaging equipment to facilitate
shelf ready packaging formats for major grocery customers
June
2012
Complete
Devoted underground electricity supply via Vic Govt support
Late
2012
Approved
Developing Morwell footprint strategy and business case for the
next generation of growth and innovation
Qtr 3
2012
In progress
15
Thank you
Questions ?
16