Tuesday, 22 September 2015 15:56

Powder plant triples yield

Written by 
Whole milk powder produced at Fonterra’s Pahiatua plant for Cuba, Sri Lanka and Venezuela. Whole milk powder produced at Fonterra’s Pahiatua plant for Cuba, Sri Lanka and Venezuela.

Fonterra says its $231 million upgrade to its dairy processing plant at Pahiatua in the Tararua district will give the company more flexibility in the products it can produce at other plants.

A new drier commissioned at the plant enables product at Pahiatua to effectively triple to 3.8 million litres daily. 

Fonterra’s managing director of global operations, Robert Spurway, says the Pahiatua plant will keep producing whole milk powder (WMP) while new value add products are made at other plants.

“The milk for this plant comes from the local region. If you were to draw a circle it’s about a 70km radius from Wellington right up the East Coast to Wairoa. This plant has reduced the amount of milk we have to send through to the Whareroa plant in Taranaki, and most importantly it’s giving us more choices about what we make through the peak of the season at other plants; we haven’t always been able to [do that] in the past.”

Spurway says the Pahiatua plant was built mostly for milk already being supplied to the co-op, but they were under pressure at the peak.

Now the increased capacity in the lower North Island will enable Fonterra to optimise the value of  farmers’ milk and add the most value year-long.

“On top of that these plants are amongst the most efficient in the world so as well as bringing on extra capacity that meets our strategic requirements we reduce our cost base and become more efficient through these sorts of expansions,” he says.

Spurway says Fonterra is pressing on with plants that produce added value products -- UHT products at Waitoa, mozzarella at Clandeboye, cream cheese at Te Rapa and sliced cheese at Eltham.  
The Pahiatua plant is described by Spurway as close to a replica of its new plant at Darfield, Canterbury. The co-op has learned from building that facility; in fact Pahiatua was built slightly faster and slightly under budget as a result. 

“It has slightly different design aspects at the foundation level -- isolators because of earthquake risk in this region relative to Canterbury. But above the ground the design and technology are almost identical to Darfield. 

“The people building these plants and, most importantly,  commissioning and running them are getting better at it each time. So far this plant start-up has exceeded our expectations.” 

The reason for the earthquake strengthening at Pahiatua surprises many people, Spurway says, noting that 18 months ago a big earthquake struck and damaged nearby Ekatahuna.

The new Pahiatua plant is now processing 3.8 million litres of milk per day, up from just 1.4 million a few months ago.  It operates 24/7 and every hour 15.5 tonnes of WMP are produced for sale in such markets as Cuba, Sri Lanka and Venezuela.

New water recycling technology is making a difference, says Bill Boakes, operations manager.

“The water we are taking out of the milk here is cleaned and used as potable water in the process. That’s the first time it’s been done in a dairy plant in NZ, though it’s done elsewhere in the world,” he says.

A waste water plant treats any water that cannot be recycled. This is then sprayed onto three nearby Fonterra farms where nitrogen and other loadings are monitored.

One hundred and eighty staff now work at Pahiatua, of whom 45 have jobs as a direct result of the upgraded. The new plant took about 800,000 hours to build.

More like this

Fonterra's in good shape

Fonterra released its interim results last month, showing a continuation of the strong earnings performance delivered by the co-op through the 2023 financial year. Here’s what Fonterra chair Peter McBride and chief executive Miles Hurrell said about the results…

China trade

OPINION: Last week's revelation that data relating to New Zealand MPs was stolen amid Chinese state-sponsored cyber espionage targeting two arms of the country’s Parliament could test the long-standing trade relations between the two countries.

Featured

Rural Change to merge with RST

The Rural Change programme, providing free private mental health professional sessions to the rural industry, is set to continue its next chapter within Rural Support Trust from 1 July 2024.

Strong growth in farm salaries - report

A new report shows farm employers across the dairy, sheep and beef, and arable sectors have continued to invest strongly in one of their greatest assets – their staff.

National

Frontline biosecurity 'untouchable'

Biosecurity Minister Andrew Hoggard has reiterated that 'frontline' biosecurity services within Ministry for Primary Industries (MPI) will not be cut…

Machinery & Products

New name, new ideas

KGM New Zealand, is part of the London headquartered Inchcape Group, who increased its NZ presence in August 2023 with…

All-terrain fert spreading mode

Effluent specialists the Samson Group have developed a new double unloading system to help optimise uphill and downhill organic fertiliser…

» Latest Print Issues Online

Milking It

Plant-based bubble bursts

OPINION: Talking about plant-based food: “Chicken-free chicken” start-up Sunfed has had its valuation slashed to zero by major investor Blackbird…

» Connect with Dairy News

» eNewsletter

Subscribe to our weekly newsletter