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Egemin to Build High-bay Warehouse For Belgium Snack Food Producer Poco Loco

Egemin Automation will soon start with the construction of a new automated high-bay warehouse for Belgian snack food producer Poco Loco. The company has been experiencing steady growth and needs more capacity. To achieve this, the company recently bought seven hectares of industrial area across the street from the company’s existing production facility. The new warehouse is part of a Eur50 million project that will allow Poco Loco to centralize its storage in one location, giving it even more control over its logistics process. For Egemin the project represents a confirmation of its competencies in automated warehouses for the food industry. The new warehouse is to go operational by early 2018.

Poco Loco produces tortilla wraps, crisps, dinner kits, Tex Mex spices and sauces. Approximately 96% of everything made in the Roeselare facility is destined for foreign markets. Until now, the products have been stored at different sites and with external suppliers. “By centralizing a major part of our warehouse, we will cut 25,000 truck trips,” says Peter Denolf, Managing Director at Poco Loco. “We will, therefore, not only save money but will also acquire more control over our own logistics. This will help us respond more flexibly to the demand of our customers.”

The new fully automated high-bay warehouse will be able to store 42,000 pallets. A 100-metre-long conveyor bridge over the public road between the production facility and automated warehouse will connect both locations. Conveyors on the bridge will transport finished pallets to the warehouse and supply raw materials from the warehouse to the production site. Finished products for customers will be picked in the warehouse and then automatically transferred to the loading zone.

Egemin Automation will deliver the complete design and delivery of the system, including all warehouse equipment and the automation of all logistics processes within this project. “We have succeeded in separating all the logistics processes and  properly aligning them,” says Joris Van Hoye, System and Concept Engineer at Egemin Automation. “The cooperation with logistics consultant Logflow, who was responsible for mapping the logistics flows of goods and the feasibility study, went very well. The warehouse, at 43 metres high and with a surface area of 8,000 sqm, makes it an impressive project. The warehouse is equipped with 11 stacker cranes and 910 metres of pallet conveyor, which ensure that 304 pallets can be moved in and out per hour. We managed to come up with a fairly simple solution to the myriad of complex logistics processes. That’s one reason why Poco Loco chose Egemin.”

The construction of the project will start soon and run for 18 months. The new warehouse is to go operational by early 2018. For Egemin, this project is an additional confirmation of its growth in warehousing and distribution solutions and its expertise in automated high-bay warehouses for the food industry.

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Clegg Food Projects Commences 19th Project With Greggs

Clegg Food Projects is building on its relationship with Greggs with the start of its 19th project for the UK’s leading bakery food-on-the-go retailer. Having worked with the company for 15 years, Clegg Food Projects has started work on Greggs’ new distribution centre project in Enfield. The development will improve efficiency and increase capacity for delivery to its stores in the south.

This year will also see the completion of Clegg Food Project’s 18th contract with the food-on-the-go retailer at their Centre of Excellence for savouries in Newcastle upon Tyne. Clegg Food Projects is currently coordinating and managing the design and installation of more efficient refrigeration equipment. The project, which has been developed in partnership with the Greggs team, includes the replacement of equipment and pipe work as well as an extension to the facilities, and is due for completion late summer 2016.

Business development director at Clegg Food Projects, John Moxon, says: “Our first ever project with Greggs was back in 2001and since then we have supported the company with projects across the UK, from Scotland to South Wales. The new distribution centre at Enfield is a significant project for us and we are working closely with Greggs to alter and refurbish the site to meet their specific needs. It’s great to be back working together.”

Clegg Food Projects provides design, engineering and construction for the food industry. For more information about Clegg Food Projects visit www.cleggfoodprojects.co.uk.

 

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TMDP LLP – Dedicated to the Food and Drink Processing Industry

MartinDesign2June2016TMDP LLP is a full service architectural design and property management agency working with, and retained by some of the largest food and drink processing companies across the UK.

With the ability to recognise and react to the demanding timescales and complex programming inherent in processing plant projects, TMDP LLP are able to offer outstanding value for money, innovative design and exceptional construction and maintenance solutions to the UK’s food and drinks processing industry.

TMDP LLP’s breadth of experience means they can deliver all types of projects within this sector, from new build, refurbishment and complete redevelopment to silo construction, plant room fit-out and production line design and installation.

By working closely with clients at every stage, TMDP LLP are able to understand and implement exactly what is required to ensure operational efficiencies and effectiveness. TMDP LLP also understand that down-time and production line disruption is critical and as such, a comprehensive programme of works is agreed at the outset of a project and rigorously maintained throughout its duration.

TMDP LLP’s track record speaks for itself and their blue-chip client base is testament to the company’s abilities and dedication to the food and drink processing industry.

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New Offering For Growing Irish Food and Drinks Industry

Leading architecture practice HLM, with offices in Belfast, is working in partnership with specialist food and drink design practice, Fusion Design, to create HLM Fusion. The new venture combines Fusion’s specialist knowledge within the food and drinks industry with HLM’s high quality architectural designs to offer innovative solutions for the burgeoning industry in Northern Ireland and the Republic of Ireland.

As a combined team, HLM Fusion provides specialist services to the food and drinks industry including strategic planning, production analysis, building design and production flows.  It also offers assistance with national and EC legislation compliance, grant and funding assessments, and applications and feasibility studies.

The service is available across HLM’s six offices in London, Sheffield, Glasgow, Belfast, Cardiff, and Plymouth and internationally, through the company’s offices in Johannesburg and Abu Dhabi.

The food and drinks industry is Northern Ireland’s biggest manufacturing sector, generating £4.5 billion to the economy last year. Similarly, the Department of Agriculture, Food and the Marine (DAFM) currently reports the agri-food sector in the Republic of Ireland contributes a value of €24 billion to the national economy and accounts for almost 10% of employment.

Karl Ruddle, who heads up HLM in Ireland, comments: “In the last two decades, the food and drinks industry in the UK and Ireland has changed dramatically, with international competition, stringent legislation and food hygiene standards inflating the cost of food production. In response to this shift, HLM and Fusion recognised the need for a single service offering expert advice to help food and drink companies to navigate the changing requirements of the landscape, whilst delivering cutting edge design.”

He adds: “As Northern Ireland plays host to the Year of Food and Drink in 2016, we have seen a recent sharp increase in expansion projects and exports, supported by initiatives such as the Agri-Food Strategy Board’s strategic action plan to support the industry in Northern Ireland. It’s an exciting time to launch HLM Fusion as a complete design service for this evidently growing industry.”

Des Gallagher, head of Fusion Design, says: “With over 25 years specialist design experience in the food and drinks industry and a demonstrable track record in delivering high quality, specialist and state-of-the-art manufacturing facilities, we are delighted to work with HLM to expand our combined offering.”

HLM Fusion has recently been retained by Kerry Foods to further develop its state–of-the-art facilities in Enniskillen. Previously completed work includes a new industrial bakery facility and cold-store for Milish Foods at its Citywest Development in Dublin. The project delivered an innovative facility to accommodate production and storage facilities, from concept through to a fully operational site.

CAPTION:

Karl Ruddle (left) and Des Gallagher.

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GEA to Equip Danone’s New Early Life Nutrition Production Plant

At the end of 2015, GEA received a major order from Danone to equip a new state-of-the-art facility for its international Early Life Nutrition brands with several production lines. The Nutricia facility will be constructed in Cuijk, the Netherlands. In particular, GEA will supply and install its Evaporation and Spray Drying Technologies. GEA’s scope of supply has a value of around Eur50 million.

“The new GEA lines will become the core technologies in Danone’s new production facility. The new plants are designed for continuous operation. They will also be highly energy-efficient, thus meeting Danone’s ambitious targets for sustainability,” comments Niels Erik Olsen, Member of the Executive Board of GEA and responsible for the Solutions Business Area.

The plant will start the production of infant formulas towards the end of 2017.

GEA is one of the largest suppliers for the food processing industry and a wide range of process industries that generated consolidated revenues of approximately Eur4.5 billion in 2014. As an international technology group, the company focuses on process technology and components for sophisticated production processes in various end-user markets. The group generates more than 70% of its revenue in the food sector.

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World’s First Earthquake Proof Whole Milk Drying Plant by GEA For Fonterra Starts Production

GEA has built a unique whole milk drying plant for Fonterra in New Zealand.  It is unique not because of its size which, at 15 tons/hour is amongst the biggest in the world; not for the speed of its construction which, at under two years is fast by global standards; but for its construction: The plant at Pahiatua is on an earthquake fault line and has been designed to withstand a 1/2500-year event without damage. It is believed to be the first plant of its kind in the world to be built in this way.

The small town of Pahiatua in New Zealand’s North Island was last hit by a major earthquake in 1934 when it was devastated by a 7.6 magnitude shock.  However, in all other respects the plant is ideally located for the dairy farms it serves, avoiding the need for tankers to traverse the Manawatu Gorge which can be dangerous in bad weather.

Building a plant in the middle of New Zealand’s earthquake zone requires special precautions.  In an effort to speed the process, and keep costs, down it was agreed not to design a new facility that would withstand tremors but to build a copy of the company’s Darfield 1 Dryer but with base isolation that would allow the building to move should a quake hit.  As well as providing all the processing equipment, GEA was also contracted as a consortium to provide the building work for the project with its partner Ebert Construction.  There are only a handful of other buildings in New Zealand that are protected in this way including the parliament building in Wellington and the country’s national museum.  For a commercial plant, this is a first.

GEA has many reference sites in New Zealand for this type of plant including Darfield 2 that operates the world’s largest milk powder dryer.  The company supplied all the processing equipment including: milk reception, storage, wet processing including standardization and homogenization, evaporation, drying, powder handling, packing and water recovery.  Most of the equipment was built by GEA locally in New Zealand with some specialist items coming from the company’s factories in China.

According to Gary Reynolds, GEA’s Project Manager, the plant was straight-forward in its design except for the base isolation construction. “All these plants are difficult because of their sheer size, but this was similar to many plants we have built in New Zealand,” he says.

The site does, however, include a reverse osmosis plant capable of processing up to 2,000,000 liters a day of ‘cow water’ (water recovered from the milk drying process) and purifying it for reuse in the plant making the new plant (P3) virtually self-sufficient in water. “This treated water is returned to the process, keeping disposal costs down and ensuring that Fonterra has no need to increase its water resource consents,” says Gary. “The RO plant will also produce boiler feed water of very high quality using less chemicals to protect the steam system from corrosion, increasing the life expectancy of the plant and reducing operating costs.”

Base Isolation

The whole plant weighs upwards of 20,000 tons, including its 40-metre-high drying tower, all of which sits on 50 triple friction pendulum bearings that will allow the whole construction to move up to 900mm in any lateral direction allowing the building to withstand a 1/2500 year event without losing its structural integrity.  Each 1.4m square bearing weighs 2.7 tons and has a Teflon center to reduce friction. The bearings were supplied by a seismic bearing specialist company in San Francisco.

Other key elements of the construction include: 3,400m3 of concrete reinforced with 400 tons of steel; the main columns are 17.5 meters long and weigh 16 tons each; and the tower walls are constructed using 517 concrete panels each of 9 tons stitched together using poured concrete.

Although the main building is base isolated the ancillary structures are not, which gave GEA some engineering challenges.  For example every supply line for steam, acid, milk, gas, chemicals or electricity has to be able to withstand the building moving by up to 900mm in any plane.  “We have used a seismic loop on all the supply lines that gives them enough slack while being supported adequately as well,” says Gary.

The human interface zones (corridors between the fixed and base isolated sections) also have to be able to move too as the building operates under critical hygiene conditions making any breach to ambient air unacceptable.

Although the plant was a copy of Darfield 1, which meant all the stainless steel components were ready well ahead of schedule, designing and building a plant such as this is not without its difficulties.  The building is made from pre-cast concrete panels and columns fabricated in Otaki, on the island’s west coast, and lifted into position.  As well as being quick to erect they also provide excellent sound insulation. Gary explained, however, that the 1200mm-square main columns were just too big to be made off site and had to be constructed and poured in situ.  However by working closely with Fonterra any potential problems were quickly overcome.

“Our goal was to change the way construction was done in New Zealand,” explains Gary.  “We brought the whole team together in a ‘community’ in which GEA and Fonterra work side-by-side. There had to be absolute cooperation between us, the client and the builder. There was some steep learning but if we had a problem we just talked it through and found a solution together.  It is a very refreshing approach.  If we had a disagreement we’d get it out in the open and deal with it.”

The plant is now commissioned and was on product on 18 August less than two years since GEA received the order.  In global terms that is quick for an ordinary plant but for a unique, market leading project like this it’s extraordinary.

Fonterra now has another industry leading site in New Zealand to which the dairy farmers of the North Island have easy, year-long access.

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GEA Infant Formula Plant For Yashili Starts Production in New Zealand

GEA has built a complete processing plant for infant formula production for Yashili, one of the Big Three producers for the Chinese market. The new plant in Pokeno, 50 km south of Auckland, was completed on time and on budget and has already started production.

With a production capacity of 50,000 tons a year, this plant is one of the largest infant formula plants in the world. It is a showcase plant for Yashili that places special focus on innovation and on the hygienic design of the process plant and buildings.

Yashili started construction on the new plant in September of 2013. GEA was chosen as the main process contractor because of its reputation in New Zealand for building dairy processing plants to the highest international standards.

The scope supplied from GEA includes all the key elements: from milk and ingredients reception, to powder production, and to final packing into 25-kg bags. All of the main processing technology from GEA assures absolute compatibility and design optimization.

Process Overview

  • Milk is received at the Pokeno site and pre-treated. Ingredients are accurately added using high shear mixing under vacuum. Vegetable oils, dry dairy powders, carbohydrates, vitamins, and minerals can then be added directly to fresh milk. The resulting formulations are cooled in batches.
  • The batches are then further concentrated by gentle removal of water under vacuum, using GEA tubular falling film evaporators.
  • The milk concentrate from the evaporators is spray-dried in a GEA MSD dryer to produce a dry powder with high functionality.
  • GEA Avapac technology is used to pack the powder into 25-kg bags.

Innovation

The plant includes a number of highly innovative technologies designed to enhance product quality and consistency, reduce noise pollution, and minimize the use of water and energy:

  • Operations on 24-hour basis. GEA has designed the plant with multiple feed lines and duplicate up-stream systems (such as for evaporation) to allow continuous, 24-hour operations of the dryer. This facility increases output, helps ensure product consistency, and avoids product quality problems associated with start-up and shut-down procedures.
  • Built-in flexibility. As well as making infant formula from liquid milk, the Yashili plant can reconstitute milk powders for introduction as ingredients. This allows greater product flexibility and more accurate management of the milk supply.
  • Inlet-air dehumidification. The GEA dryer uses dehumidified air and is one of the first spray dryers in New Zealand to benefit from this feature. By dehumidifying the inlet air it is possible to compensate for changes in humidity throughout the day or year, thereby optimizing dryer efficiency and avoiding upsets in the drying process. It also ensures a greater consistency in the properties of the final powder.
  • Water recovery. The water treatment system uses reverse osmosis to process water evaporated from the milk, which converts it into high-quality water for reuse within the plant. This reduces water consumption and minimizes disposal costs.
  • Exhaust heat recovery. A variety of best-in-class energy recovery techniques are used to recover waste heat and return it to the process. The high dryer-exhaust temperatures associated with the production of infant formula makes heat recovery both practical and cost-effective.
  • Reduced noise. Special care has been taken to reduce noise from the plant, owing to its location near residential areas and its 24-hour operation. The building has been designed to contain noise, including the attenuation of noise at ventilation and process exhaust openings. Equipment is also strategically selected and located to minimize overall noise levels from the site.
  • Advanced process control. Legislators, retailers, and insurers are placing increasingly stringent demands on the traceability of food products: in particular, food for infants and the new-born. To meet these demands, GEA has included modules from its OTAS software suite for higher-level supervisory control of the Yashili plant. These modules ensure transparency in the production sequence, effective use of resources, and high product quality. The GEA OTAS Track & Trace module especially allows Yashili full and transparent traceability of raw material and ingredient inputs, throughout the process and into the final product.

In addition to process innovations, GEA took on responsibility for all process buildings. This took place in conjunction with its partners Ebert Construction Ltd. for the building work and Silvester Clark Ltd. for building design. This partnership ensured high-level optimization of building space to fully match process needs.

Chris Burt is the engineering manager for GEA in New Zealand. He reported that the Pokeno plant had been a challenging project, but that the company had been able to draw on its long experience of building similar facilities elsewhere in the country and around the world. “We have succeeded in including interesting innovations for Yashili,” he explained. “These have combined to optimize the plant in terms of its productivity, flexibility, and sustainability. It is really a world class facility.”

Terry Norwood is the Operations Manager for Yashili New Zealand operations and has seen the project through from conception until the present. “We have a plant here that represents the best in class in many aspects and that produces an excellent product,” he said. “GEA has been a great partner in this project.”

The Pokeno plant is already producing products and will move into full production in accordance with Yashili’s commercial needs.

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Brown-Forman Breaks Ground on New $50 Million Irish Distillery

Leading US Drinks firm Brown-Forman Corporation, the owner of the Jack Daniel’s, Southern Comfort and Woodford Reserve brands, has started construction of its new the $50 million (€44 million) Slane Distillery in Ireland. The distillery, which will also include a Visitor Centre, is being built on the historic Slane Castle Estate in County Meath, home of Henry Conyngham, the eighth Marquess Conyngham, and his son Alex Conyngham, Earl of Mount Charles.

Brown-Foreman bought all shares of Slane Irish Whiskey Company from the Conyngham family earlier this year. The Conynghams remain centrally involved in the development of the new distillery and the new whiskey brands which will be introduced in early 2017.

This is the first new distillery Brown-Forman has built outside of the US and represents its entry into distilling Irish whiskey, one of the fastest growing spirits categories over the last few years. When completed by the end of 2016, Slane Distillery will create nearly 25 new full-time jobs while the construction process will support approximately 80 jobs. The Slane Distillery and Visitor Centre will be a welcome new attraction to the Boyne Valley tourism trail.

According to Lawson Whiting, executive vice president and chief brands & strategy officer for Brown-Foreman, Irish whiskey is one of the most exciting spirits categories in the world and Slane provides the perfect opportunity to begin distilling Irish whiskey. “Brown-Forman brands are founded on heritage, quality and authenticity and there is nowhere as real as this beautiful and historic part of Ireland. We will leverage our wood and whiskey making prowess to create world class whiskey at Slane,” he says.

The distillery and visitor centre, which is in the historic stables complex adjacent to the castle, will see the 18th Century buildings restored and converted to house both the production operations and the consumer experience. The first Slane Irish whiskeys will be launched to market in early 2017 – initially using high quality whiskey purchased from other Irish distilleries and finished to Slane’s exacting recipes and specifications while the first whiskey from the distillery is laid down to mature. Upon completion it will have a potential output of more than 600,000 cases.

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2 Sisters Invests £55 Million to Drive Growth in Meal Solutions

2 Sisters Food Group, one of the UK’s largest food producers, is investing £55 million in its Meal Solutions Division to support further growth, create state-of-the-art manufacturing facilities and secure jobs.

2 Sisters’ Meal Solutions produces a range of products including ready meals, soups and sauces. The division is wholly focused on own-label products, and predominantly produces ready meals and soups and sauces for Marks & Spencer out of four factories – Pennine Foods in Sheffield, Rogerstone in South Wales, Carlisle and Grimsby. The majority of the investment will be used to completely rebuild Pennine Foods, with the remainder being allocated to refurbish and expand capacity at both Rogerstone and Carlisle.

Pennine is a purpose-built site, originally established in 1986, which has now reached full capacity. A £38 million rebuild will develop best in class commercial and operational processes to support continued innovation, expand capacity and drive further profitability. The strengthened operational platform will enable 2 Sisters to continue to grow its position as the market leader in ready meals production in the UK.

NorthernFoodsChilledTo avoid disruption for customers, work at Pennine will be phased with some capacity transferring to both Rogerstone and Carlisle from April 2016. The transferred capacity will remain at those sites creating the opportunity for new ranges to be produced at Pennine once work is completed at the end of 2017. The refurbishment programme will help safeguard up to over 800 jobs at Pennine.

Simon Wookey, divisional managing director at 2 Sisters Food Group, says: “Our investment in the Ready Meal Chilled Division is fully supported and welcomed by our customers. We continue to see an opportunity to drive further market share growth in the ready meal sector supported by a new state-of-the-art factory in Sheffield.”

He adds: “On average the ‘Chilled Ready Meals’ sector is growing at roughly 3% per annum, and our chilled division is outpacing that growth. It will also create significant opportunities to improve the way we operate as a business whilst also helping to safeguard and potentially create jobs in all our factories.”

Paul Willgoss, director of food technology at Marks & Spencer, says: “This is a significant investment by a key supplier. It supports our growth plans and will help us continue to deliver the highest quality and innovation in our products.”

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Mondelēz International Unwraps New Production Line at Bournville

Mondelēz International has officially opened a new state-of-the-art production line at its chocolate factory at Bourville, the home of Cadbury in Birmingham. The new facility has been installed as part of a £75 million investment in Bournville by Mondelēz International to make its Cadbury Roses and Heroes assortments and Cadbury Dairy Milk bars. Announced by the company last year, it secures the next generation of chocolate manufacturing at the site.

The new line was opened by British Business Secretary Sajid Javid (pictured centre). During his visit the Business Secretary got a taste for the business by touring the production line. He also visited a new training facility and met apprentices and staff.

Mary Barnard (pictured left), President of Northern Europe at Mondelēz International, says: “We were delighted to welcome the Secretary of State to Bournville to officially open the first of our new state-of-the-art manufacturing lines. This marks an important milestone in our journey to secure the next generation of manufacturing at this iconic site.”

MondelezCadburyBournville2CompressedShe adds: “Our £75 million investment into Bournville is not just about new machinery, it’s also about investing in the people who work here. We welcomed the opportunity for Mr Javid to visit our new training facility and meet with apprentices and operators to hear first-hand about the new skills, knowledge and qualifications they are gaining.”

Mondelēz employs more than 4,000 people in the UK across nine sites, including five manufacturing sites, a Global Centre of Excellence for Chocolate Research and Development in Bournville, and Global Science Centre in Reading.

Food and drink is the largest manufacturing sector in the UK. It has a turnover of £95.4 billion and employs about 400,000 people – more than the population of Leicester.

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Marston’s Moves to Keep Pace With Growth in Home Market

UK brewer and pub operator Marston’s is ramping up warehouse capacity at its main brewery by as much as 45 per cent in a bid to keep pace with the thriving take-home beer market. Supermarkets and off-licences sold more beer than pubs and clubs for the first time last year as booming demand hit record levels. Marston’s saw take-home trade grow by more than 10 per cent in the last 12 months alone.

The company is putting up four new warehouses at its main Burton brewery to significantly increase storage capacity. The buildings, supplied by Spaciotempo, will create room for as many as 14 million bottles of beer and are the final stage of major plans to increase production at the site following the installation of a new £7.4 million bottling plant.

Sales of beer in pubs dwindled by 0.8 per cent last year, according to figures from the British Beer and Pub Association, while ‘off-trade’ business shot up by 3.5 per cent – taking the home market past the retail trade for the first time on record.

According to Marston’s, the take-home market for lager and premium bottled ale has risen by more than 10.5 per cent year on year.

Emma Gilleland, director of brewing at Marston’s, and Scott Jameson, managing director of Spaciotempo.

Emma Gilleland, director of brewing at Marston’s, and Scott Jameson, managing director of Spaciotempo.

Emma Gilleland, director of brewing for Marston’s, says: “We’ve seen significant growth in the take-home market over the last couple of years. More people than ever before are enjoying a drink in the comfort of their own home, so we’ve moved to ensure supply keeps up with demand. The bottling plant, which opened last year, was the first stage of that plan and these new storage facilities will give us the huge amount of extra warehouse capacity we need.”

Spaciotempo is replacing two of the brewer’s existing warehouses at the Burton site with new units that will create a massive 8,500 square metres of storage and space for 13,500 pallets.

Work to erect four 6m-high buildings, each measuring 30 x 85m, is expected to be completed in just three months.

The project is one of the biggest to date for Spaciotempo, which supplies a range of innovative temporary and semi-permanent buildings to a wide variety of industries.

Emma Gilleland adds: “Spaciotempo have played a key role in helping us to grow the business. They’re providing a quality, cost-effective and long-term solution that meets our needs perfectly. Our forecasts indicate the home market will continue to grow and this project will satisfy demand for the next 18 months.”

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Egemin Automation to Build 44-metre-high Deep-freeze Warehouse For Agristo

Egemin Automation will build a new automated deep-freeze warehouse for Belgian producer of frozen French fries Agristo on its production site in Nazareth in East Flanders. The investment is needed to support Agristo’s projected growth. The new high-bay warehouse will be 44 metres high and eight AS/RS stacker cranes will be deployed to store frozen French fries.

With its 15 storage levels and eight crane aisles it will provide space for 24,000 pallets or 17,000 tons of frozen fries. Egemin already did a similar project for Agristo in Tilburg, the Netherlands, in 2012. The completion of the deep-freeze warehouse in Nazareth is planned for March 2016.

The deep-freeze warehouse will be built next to the existing plant. Egemin Automation is responsible for the silo construction of the warehouse and a complete conveyor system with pallet lifts and cranes for all logistics movements to and from the warehouse. Egemin will also perform the installation and management of the software systems.

The clad rack structure of the warehouse is specifically designed to be durable in its use of energy. The eight automated pallet cranes are equipped with an internal energy recovery system. The energy released during lowering and braking of the crane is recovered internally and used for a different crane movement such as lifting and moving. The cranes will save up to 20% of energy in this way.

“Agristo also asked us to keep the technology as simple as possible,” says Marcel Spruijt, sales manager at Egemin Automation. “The less complex, the more reliable the installation and we will possibly experience fewer faults. That way the frozen foods producer does not need to deploy its people inside the warehouse. After all, the temperature there is always around -25 degrees Centigrade and the oxygen level is controlled to prevent fires.”

Agristo produces day and night with a logistics service that operates 16 hours a day, five days a week. This creates a large buffer which one must be able to move quickly. “The production provides 120 pallets per hour. Our installation can handle twice that,” says Marcel Spruijt. “That is partly because Agristo opted to install eight cranes in the warehouse. They can load the lorries immediately so they do not have to waste too much time waiting.”

“The project in Tilburg was very successful and everything is working to the client’s satisfaction,” says Marcel Spruijt. “Nazareth will not be an exact copy, but an improved version of the warehouse in Tilburg. It will be three metres higher and the pallets will be stored even more efficiently.”

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Allied Bakeries Completes £210 Million Capital Investment Programme

Allied Bakeries, part of Associated British Foods, has completed its £210 million capital investment programme designed to create a state-of-the-art baking capability across the UK and ensure the reliable supply of high quality bread to customers. The programme has also set a new benchmark for standards of food safety in the bakery sector and has enhanced workplace safety.

The five-year upgrade programme was completed with the modernisation of the Glasgow bakery during last year and the recent installation of a new £31 million bread plant in Stevenage which is capable of producing 9,000 loaves per hour. Allied Bakeries’ sites at Stockport, West Bromwich, Glasgow and London have also benefited from investment.

Allied Bakeries produces a range of bakery products under the Kingsmill, Sunblest, Allinson and Burgen brands, with flour and semolina produced by sister company, Allied Mills. The investment programme has also facilitated greater flexibility in new product development with recent innovations including include Kingsmill Great White, a white bread with as much fibre as a wholemeal loaf, new re-sealable packaging for Kingsmill wraps, and Sandwich Thins.

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Dunbia to Invest £27 Million in Northern Ireland

Dunbia Group is to invest £27 million at its Dungannon site in Northern Ireland to establish an intelligent boning hall and to upgrade production lines to increase output and support export growth. The capital investment programme will result in the creation of 209 new jobs at Dungannon over the next three years.

Dunbia Northern Ireland’s Dungannon facility employs almost 1,000 people in the procurement, slaughter and de-boning of cattle and sheep, as well as wholesale distribution and retail packing of beef and lamb.

The investment was secured for Northern Ireland by Invest NI, which has built up a strong relationship with Dunbia NI. Invest Northern Ireland has offered £2 million of support and will continue to work closely with the company as it grows.

Northern Ireland’s Enterprise, Trade and Investment Minister Arlene Foster says: “Dunbia is investing in innovative technology and production processes to enable it to maximise the return on its resources and remain cost-competitive. The new boning hall will help the company achieve improved butchery efficiencies and economies of scale, while the installation of new production lines using the most modern automated retail butchery will increase retail packing efficiencies.”

She adds: “The meat sector plays an important part in our economic success and the sector has continued to grow, despite the downturn. This kind of investment is significant, not just for the future long-term sustainability of Dunbia, but also for its positive impact on the agri-food supply chain and the red meat sector as a whole.”

Dunbia NI is part of the Dunbia Group which employs around 4,000 people over 13 sites.

Jim Dobson, managing director of Dunbia Group, says: “Innovation has been at the heart of Dunbia’s success and this investment in new production technology will create a centre of excellence for beef deboning. It will help us to maintain our position as a leading meat processor in the UK and Ireland and to deliver on our growth strategy over the next three to five years. Invest NI’s support, and its ongoing advice, were important factors in our decision to make this investment at our Dungannon facility.”

CAPTION:

Minister Arlene Foster is pictured with Jim Dobson, managing director of Dunbia Group.

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Glanbia Ingredients Ireland Opens New €180 Million Nutritional Ingredients Plant

Ireland’s leading dairy ingredients company, Glanbia Ingredients Ireland, has commenced production at its new, state-of-the-art nutritional ingredients plant at Belview in County Waterford, so completing a €200 million investment programme designed to increase processing capacity in readiness for the abolition of EU milk quotas.

Glanbia Ingredients Ireland processes1.6 billion litres of milk annually or 30% of Ireland’s milk pool into a range of dairy ingredients for export to more than 50 countries. The company is performing strongly with profits of Eur39 million.

Glanbia Ingredients Ireland supplies a range of ingredients to the infant formula market and exports enriched milk powder to markets including West Africa, Middle East and Asia in consumer-ready formats. It also sells a range of dairy proteins into the clinical and sports nutrition sectors. The company is one of the key Irish dairy processors supplying cheese and butter to the Irish Dairy Board (which is sold under the Kerrygold brand). Glanbia Ingredients Ireland currently employs 668 people across its five sites in Ireland and in representative offices overseas. The company has market bases in Ireland, Germany, the US, Dubai and Senegal.

Jim Bergin, chief executive of Glanbia Ingredients Ireland.

Jim Bergin, chief executive of Glanbia Ingredients Ireland.

Glanbia Ingredients Ireland is a joint venture between Glanbia plc, the global nutritional solutions and cheese group, and Glanbia Co-operative Society, which is the main shareholder in Glanbia plc. Glanbia Ingredients Ireland is 60% owned by the Glanbia Co-operative Society and 40% owned by Glanbia plc. Glanbia Co-operative Society has an option to buy Glanbia’s 40% stake within six years. In the process of forming the joint venture in 2012, Glanbia Co-operative Society reduced its shareholding in Glanbia plc from 51.4% to 41.4%.

€180 Million Investment

Glanbia Ingredients Ireland’s new greenfield facility at Belview has literally broken new ground in the Irish dairy industry and set new standards internationally. “Some Eur180 million has been invested in our new nutritional ingredients plant at Belview, with support from Enterprise Ireland. It is the largest single dairy investment in the history of the State and the largest infrastructure investment by an indigenous company since 1929,” points out Jim Bergin, chief executive of Glanbia Ingredients Ireland.

The new facility will create 1,600 direct and indirect jobs, while contributing an estimated Eur400 million per annum to the economy – with particular benefit to farm families and rural communities.

The new plant has a weekly processing capacity of 19 million litres of milk. It has been designed to manufacture specialised milk powder products and nutritional ingredients to meet the demands of multi-nationals in infant formula and other industries operating in Asia, North Africa and around the world. Belview will produce concentrated skimmed milk, enriched milk powder, infant formula grade skimmed milk powder, infant formula grade whole milk powder and cream.

“Belview is a scalable facility that is also extendable. It is Ireland’s largest milk powder plant, and will produce high end ingredients produced to rigorous quality standards. A key feature for our customers is that we offer an owned and traceable milk supply from our farmer base of 4,800 suppliers,” Jim Bergin explains.

Belview will produce concentrated skimmed milk, enriched milk powder, infant formula grade skimmed milk powder, infant formula grade whole milk powder and cream.

Belview will produce concentrated skimmed milk, enriched milk powder, infant formula grade skimmed milk powder, infant formula grade whole milk powder and cream.

Fast Track Project

The fast track project was delivered on time and on budget from ground-breaking in May 2013 to first processing of milk in December 2014. At peak more than 750 people were employed on the site. The safety record of the programme is commendable – approximately 1.5 million man-hours operated with only one HSA recordable incident.

The project brought together a broad range of global expertise and suppliers. In addition to Ireland, equipment was designed and supplied from countries across Europe including Denmark, France and various Eastern European countries, and from further afield such as New Zealand and China.

“The project also relied upon the support of a wide range of agencies and groups, without whom the project would not have succeeded – Local Government, IDA, Enterprise Ireland, ESB, Bord Gais and local residents, to name a few,” stresses Jim Bergin.

Advanced Design

The nutritional ingredients plant at Belview has been built to Infant Formula Spec and European Design Hygiene guidelines. The new facility is highly automated with a focus on best in class efficiency for water and energy usage and quality standards. There is also an emphasis on cleaning and re-cycling of water, as well as utilisation of some of the most energy efficient process equipment available. Heat recovery is a corner-stone of the plant’s design and operation, as is the operational model whereby energy inefficient processing (short periods) are avoided. Clean energy sources have also been utilised where possible.

“Thanks to cutting edge technology, the plant will produce a range of nutritional ingredients which are top quality and low micro, ensuring a suitable application across a range of infant and clinical nutrition industries,” he says. “Our low micro dry blend powders will be used in some of the world’s most recognised infant formula brands from Stage One.”

GlanbiaIngredientsIrelandLogoInternational Standing

Belview compares favourably with other dairies internationally in terms of scale, technology and environmental performance. With regard to the technologies utilised and planned efficiencies, the facility is best-in-class.

Equipped with two 7.5 tonne/hr dryers, Belview is comparable in size with other European plants of this type, although smaller than the large scale processing plants in New Zealand. The facility will process approximately 19 million litres of milk per week at peak.

Jim Bergin comments: “International expertise on hi spec builds was brought in to work on this project. Specifically, 3D modelling was utilised such that each and every component – floor, wall, pipe, valves, instruments etc – was modelled electronically and, thereafter, installed exactly in accordance with the model. This modelling allowed for the design to be fully reviewed and validated before installation, avoiding changes and providing assurances in relation to the safety, quality, operability and maintainability of the facility.”

Target Markets

The plant at Belview has been developed specifically for the export market with high growth developing regions in particular being targeted. It will complement the other sites within Glanbia Ingredients Ireland’s operations.

“The Belview site will allow us to develop a range of specialised infant formula grade nutritional ingredients which will enable a deeper penetration of the Nutrition and Health and Wellness industries which we already supply with our portfolio of advanced milk proteins,” he remarks. “These are currently produced at both our Ballyragget and Virginia plants alongside our enriched milk powders, butter, cheese, cream, and whey concentrates. We also recently acquired Wexford Creamery, which produces a range of cheeses, and through a joint venture in Carrick on Suir we make technical butters for the baking industry.”

Jim Bergin adds: “We are seeing significant growth in many of the industry sectors we supply into, particularly in the area of Health and Wellness. The clinical nutrition and sports nutrition industries are worth Eur16 billion and are currently growing at greater than 6% per annum.”

Additional Investment

A key feature for customers is that Glanbia Ingredients Ireland can offer an owned and traceable milk supply from its farmer base of 4,800 suppliers.

A key feature for customers is that Glanbia Ingredients Ireland can offer an owned and traceable milk supply from its farmer base of 4,800 suppliers.

In addition to the establishment of the new nutritional ingredients plant at Belview, Glanbia Ingredients Ireland has also been modernising and expanding its existing facilities at Ballyragget in County Kilkenny and Virginia in County Cavan under a total investment package worth over Eur200 million.

At Ballyragget, Glanbia Ingredients Ireland has significantly upgraded its butter plant. The company has been processing butter since 1968, when the Ballyragget plant was first opened. “Remaining at the heart of the business ever since, we now have a wealth of experience to draw on across anhydrous milk fat (AMF), butter oil/butter oil fractions, salted and unsalted sweet cream butter, lactic butter and technical butter. Combined with our high quality, sustainable milk pool, this allows us to serve markets all over the world with exceptional butter ingredients and branded butter products,” Jim Bergin explains.

The Ballyragget facililty produces a range of butters, which are supplied to a range of global customers from branded retail butters such as Kerrygold through to top quality baked goods and biscuits. The new butter plant will facilitate a 45% increase in capacity from 55,000 MTs to 80,000MTs by 2020.

Ballyragget is one of Europe’s largest integrated dairy processing facilities. In 2012, Glanbia Ingredients Ireland also invested Eur21 million in a new whey plant at Ballyragget to consolidate the site’s leadership position into the future. “We are still witnessing increasing customer demand for whey protein isolate – which is a very pure form of whey protein, suitable for various nutritional applications,” he says.

New Milk Protein Plant

The nutritional ingredients plant at Belview has been built to Infant Formula Spec and European Design Hygiene guidelines.

The nutritional ingredients plant at Belview has been built to Infant Formula Spec and European Design Hygiene guidelines.

At its Virginia site, Glanbia Ingredients Ireland recently invested Eur7.8 million in a new milk protein plant enabling production of the next generation of advanced milk proteins SolmikoHD and SolagoHD. Opened in December 2014, the new plant processes milk from counties on both sides of the border between the Republic of Ireland and Northern Ireland. The milk proteins are used by the global clinical nutrition, sports and consumer food industries. The investment at the plant will increase milk protein capacity from 4,000 to 10,000 tonnes.

In addition to producing enriched milk powders for export markets, the Virginia site is the only supplier of cream for the Bailey’s liqueur brand, owned by global drinks giant Diageo.

Development Strategy

Glanbia Ingredients Ireland has now completed the first part of its 2020 growth strategy designed to ensure the company is well prepared for the processing of an increased milk supply following the abolition of milk quotas.

Jim Bergin comments: “Phase 1 provided for a capital investment programme of Eur200 million in high spec processing infrastructure. Our new nutritional ingredients plant at Belview is the final piece in place of that capital investment outlay. Phase 2 is the development and expediting of our innovation agenda to drive the development of high spec ingredients for the Health and Wellness and Nutrition industries.”

Dairy Industry Outlook

So how does he see the outlook for the Irish dairy industry in light of the abolition of EU milk quotas?

“Quotas have been in place since 1984 and their removal at the end of March has the potential to radically transform Ireland’s rural economy. For the first time in 30 years, Irish dairy farmers can increase their production without having to purchase additional milk quota rights. The current farming generation has never known farming without quotas so this really is a generational opportunity,” he replies. “It represents a momentous juncture, not just for dairy farmers but for Ireland’s export economy.”

Jim Bergin draws a parallel with the situation in New Zealand, which like Ireland has a large dairy industry and grass-based system naturally suited to sustainable dairy farming. When milk quotas were introduced in 1984, Ireland and New Zealand both produced approximately 5 billion litres annually. However, in the absence of a quota regime New Zealand now produces 20 billion litres of milk annually.

“The removal of milk quotas gives Ireland a unique opportunity to increase milk production and bring an additional Eur1 billion into the Irish economy.” He continues: “The strategic ambition of Glanbia Ingredients Ireland is to grow in international markets, particularly in high growth developing regions.”

Strong Market Fundamentals

The market fundamentals are strong and the outlook is bright. Global consumption of dairy products is forecast to grow by 2% to 3% year-on-year until 2025. This is based on solid market demand that is built on sustainable global trends. He also points out that the earth’s population is expected to grow by almost 1 billion extra people during this period with the fastest growth rates in Africa and South East Asia.

Glanbia Ingredients Ireland’s new Milk Protein Plant at Virginia was officially opened by representatives from the Governments of the Republic of Ireland and Northern Ireland - Heather Humphreys, Minister for Arts, Heritage and the Gaeltacht, and Arlene Foster, NI Minister for Enterprise, Trade and Investment. Pictured (left to right) are: Liam Herlihy, chairman of Glanbia Ingredients Ireland; Heather Humphreys; Arlene Foster; and Jim Bergin, chief executive of Glanbia Ingredients Ireland.

Glanbia Ingredients Ireland’s new Milk Protein Plant at Virginia was officially opened by representatives from the Governments of the Republic of Ireland and Northern Ireland – Heather Humphreys, Minister for Arts, Heritage and the Gaeltacht, and Arlene Foster, NI Minister for Enterprise, Trade and Investment. Pictured (left to right) are: Liam Herlihy, chairman of Glanbia Ingredients Ireland; Heather Humphreys; Arlene Foster; and Jim Bergin, chief executive of Glanbia Ingredients Ireland.

Glanbia Ingredients Ireland will work through its global customer partnerships to target both developed and emerging markets. “For example, there are new and emerging middle classes with higher incomes in major markets such as China and the Middle East. There is increased awareness of the benefits of dairy products, westernisation of diets and a growing focus on health and wellness.”

Jim Bergin elaborates: “The new plant at Belview is also good news for other Irish dairy companies, as we have manufacturing contracts with eight other domestic processors which will be open to development or expansion from the Belview plant. Belview is a scalable facility and so it will also provide platforms for further collaboration in the industry.”

Green Credentials

The new plant at Belview along with Glanbia Ingredients Ireland’s other recent investments are expected to further enhance Ireland’s reputation as one of the best dairy producing countries in the world. “Ireland’s green credentials provide a differentiated positioning in the global marketplace where our grass-fed, pastured and family farm method of dairying produces a highly sustainable range of quality ingredients, making Ireland highly cost competitive. Glanbia Ingredients Ireland has prioritised sustainability as a key focus for its business,” he remarks.

Indeed, Glanbia Ingredients Ireland’s Belview, Cavan and Kilkenny facilities represent a major statement of intent by the company and on behalf of the Irish dairy industry. “The Belview site will see production and manufacturing on a global scale brought to the South East of Ireland and demonstrates our confidence in, and commitment to, our suppliers and the Irish economy.”

GlanbiaIngredientsIrelandLogo2The Glanbia Ingredients Ireland chief executive concludes: “The Government support, through Enterprise Ireland, is a further, significant endorsement of this vision and a vote of confidence in the Irish dairy industry and indeed in Glanbia Ingredients Ireland and our milk suppliers. Up until now the only disadvantage Ireland has had in the dairy field has been quota-imposed supply restriction. The new era of dairy enabled by the removal of quotas at the end of March will allow us to break free of these shackles and significantly ramp up supply capability.”

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Glanbia Ingredients Ireland Belview – A Fast-track Project Delivered on Budget on Time

In three years Glanbia Ingredients Ireland’s Belview facility has literally come from a green field in County Kilkenny to a world class 24,000 sq m dairy plant built to infant formula standard. The largest single capital investment (€180 million) in Ireland by an indigenous Irish company, Belview was designed and project managed by PM Group to process up to three million litres of milk per day into a range of specialised milk powders and nutritional ingredients to meet the demands of multi-nationals in infant formula and other industries around the world.

PM Group began the project in 2011 initially working on the concept design and site selection and continuing through planning applications, IPPC licence application, full engineering design, procurement, construction management, commissioning and start up assistance to deliver first milk in December 2014.

PMGroupGlanbia3Projects of this size inevitably pose many challenges around design, safety co-ordination, scheduling, cost control and quality.

Substantial Design Co-ordination

This type of complex process driven design project required substantial design co-ordination between the various engineering disciplines and the process (GEA) and utility contractors. The main feature of the site is a tower in excess of 40 metres, housing two large spray dryers. PM Group used the latest 3D modelling design tools to design a fully integrated facility.

A fast track Construction Management approach was implemented starting with an enabling works contractor appointed in May 2013. Multiple other trade contractor appointments followed, culminating in the plant being ready to receive first milk in December 2014 on schedule. The construction management approach combined with strong cost management throughout the design and build ensured the facility was delivered on time and within budget.

Construction Safety

PMGroupGlanbia1According to John Harte, PM Group’s Project Manager: “Construction safety was paramount at all times with a peak of 785 workers on site and over 1.5 million construction manhours executed in total. In excess of three thousand people received safety induction training on site during the course of the project.”

GMP is a particular focus for a facility of this size which featured 300,000 cu m of excavations, 40,000 tonnes of concrete, 35,000m of pipe, 536km of cable, 10,000 sq m of ducting and 1,180 instruments and all installed to the highest standards.

“The Glanbia Ingredients Ireland Belview project had quite an impact on our dedicated food engineering team. We have extensive experience in the design and build of major dairy and infant nutrition projects in Europe and Asia. But to complete such a world class project close to our HQ was a fantastic experience,” says Tom Waters, Food Sector Director at PM Group.

For further information visit PM Group at www.pmgroup-global.com.

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Latest GEA Technology Creates One of Europe’s Largest and Most Efficient Dairy Plants For Glanbia Ingredients Ireland

It was just 18 months ago that Glanbia Ingredients Ireland awarded GEA a contract to build one of Europe’s largest and most efficient milk processing plants in Belview, Ireland. The first production started in December, 2014: on time, on budget and exactly as planned.

Belview uses the latest dairy technology from GEA to process three million litres of milk a day into more than 100,000 tonnes of dairy powders a year. GEA supplied the complete plant drawing on the company’s full scope of dairy process technologies and components from milk reception through standardization, evaporation and drying to powder transport and packing. Also the complete automation package was supplied by GEA.

Glanbia’s new nutritional ingredients plant builds on the latest in dairy technology, and it is a showcase for the most modern dairy plants in the world. It has been designed to ensure the most efficient operation in terms of overall equipment efficiency, energy and resource consumption while producing products of the highest quality in a safe environment.

Building a plant this size on an 18 month schedule, delivering it on time and budget, requires solid expertise in managing large projects. GEA’s responsibility included the entire project from process design to project delivery. “Projects like this require careful planning and close coordination between our project management teams, headed by a project director, and the customer,” explains Jan Samsson, Project Director with GEA, and responsible for the Belview project. “We structure projects around that with a sponsor group representing the customer, the builder and GEA. It helps get ahead of challenges and thereby reduces risk for all.”

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EPS Delivers For Glanbia Belview

EPS were awarded the contract at the new Glanbia Ingredients milk processing facility in Belview Port, Co. Kilkenny through their consultants, PMG (Project Management Group), to provide a Waste Water Treatment Plant & Water Softening Plant to service the resulting production operations associated with the new build. The rigid programmes demanded by both these projects required EPS to take creative steps so as to maintain progress with the client’s target dates. By opting to fabricate large sections of the plant offsite allowed EPS to improve delivery time, installation time, reduce associated health & safety risks, reduce disruption on site and reduce associated on site costs.

EPS2March2015The standalone waste water treatment plant comprises the following principal steps: a stainless steel lined pumping station capable of a maximum peak demand duty of 680 cu m/hr, the provision of 4 No. glass lined steel balance tanks for pH buffering/correction, the removal of fats, oils & greases (FOG’s) through the use of a dissolved air floatation (DAF) tank, and the provision of analytical sampling & monitoring instrumentation. The water softening plant principally comprised 3 No. GRP ion exchange softening tanks which operate on a cyclical basis, a salt saturator tank & brine day tank.

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Arla Foods Inaugurates New Production Facilities in Germany

European dairy co-operative Arla Foods has officially inaugurated a brand-new production area at its site at Pronsfeld in Germany. A total of about €110 million was invested in the construction of a new milk drying tower, a new creamery and additional milk preparation and processing capacity. This represents a further step in the company’s continuous, successful development of its Pronsfeld location in Rhineland-Palatinate.

The Pronsfeld location has evolved into one of the largest dairy production locations in Europe over the past 50 years. As early as 1967, dairy products with a remarkably long shelf life were being produced in the region with great success – this production continued under the auspices of Milch-Union Hocheifel (MUH) until 2012.

Until now, around 1.4 billion kilogrammes of milk have been processed annually in Pronsfeld. Thanks to the new production facilities, it will be possible to process an additional 450 million kilogrammes of milk annually, starting immediately. This corresponds to a volume of 40,000 tonnes of butter and 42,000 tonnes of milk powder annually.

“We will be using our various powdered milk products to supply our growth markets in Asia and Africa as well,” says Tim Ørting Jørgensen, head of Arla’s Consumer Central Europe division (CCE).

German dairy butter and the already highly successful blended spread Arla Kærgården® will be produced here for the German market and for the Arla countries in Central Europe. This makes the Pronsfeld location the largest production site in Arla’s entire network, as well as Arla’s centre of excellence for long-life dairy products.

“To my mind, this ultramodern dairy production facility is first and foremost a testament to forward-thinking farmers who have ventured to take a bold step forward. Instead of ducking their responsibility, they have taken their future into their own hands. As the chairman of a cooperative, that is something that makes me very proud,” says CEO of Arla Foods, Peder Tuborgh.

The company has placed particular emphasis on the sustainable – that is, energy-efficient – design of the new facilities. The result of the initiative is a series of production facilities that are not only state-of-the-art, but also live up to Arla’s principles of sustainability and corporate responsibility.

CAPTION:

From left: Jürgen Wolff (site director of Pronsfeld Dairy), Peder Tuborgh (CEO of Arla Foods), Malu Dreyer (Chief Minister of Rhineland-Palatinate), and Tim Ørting Jørgensen (Executive Vice President and head of Arla Central Europe).

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Mondelez International Constructing $90 Million Biscuit Plant in Bahrain

Mondelez International has laid the cornerstone for construction of its new $90 million biscuit plant in Bahrain as the world’s leading maker of chocolate, biscuits, gum and candy seeks to tap rising demand in the Middle East and Africa for company brands such as Oreo, Ritz and TUC biscuits.

The company announced the project in October 2014. Full commercial production is scheduled to start early next year.

“Demand for our biscuits in the Middle East and Africa has been growing at double-digit rates and investing in a state-of-the-art facility in Bahrain will enable us to capitalize on this,” says Daniel Myers, Mondelez International Executive Vice President, Integrated Supply Chain. “This new investment is part of our journey to reinvent our supply chain around the world to meet growth demands, while also reducing costs and improving productivity.”

Mondelez International’s supply-chain reinvention plan is expected to deliver $3 billion in gross productivity savings, $1.5 billion in net savings and $1 billion in incremental cash during 2014 to 2016. These savings will be a primary driver of significant improvements in the company’s base operating-income margin in the near term.

The Government of Bahrain has reclaimed the necessary land for construction of the new plant, which will have a total capacity of nearly 90,000 tons per year. In the initial two- to three-year phase, the plant will operate four biscuit-manufacturing lines producing – in addition to Oreo, Ritz and belVita – Prince and TUC biscuits, as well Barni cakes.

This is Mondelez International’s second major investment in Bahrain. The world’s leading snacks powerhouse has already invested more than $75 million in developing a Kraft Cheese and Tang powdered-beverage plant in Bahrain which has been operational since 2008. With a production capacity of 110,000 tons per year, the existing facility employs more than 240 people and has injected over $250 million in the local economy since construction through wages, and purchase of goods and services.

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GEA Builds New Dairy Powder Plant

GEA Process Engineering in New Zealand has built a complete process plant for infant formula and goat milk powder for its long-term customer Dairy Goat Co-operative (DGC) in Hamilton. Working closely with DGC, GEA has used its experience in plant design to develop a highly innovative plant that provides multiple benefits including: improved product quality, reduced energy costs and reduced water consumption.

GEA has been a long-term partner with the Dairy Goat Co-operative since 2003 when it built the company’s original infant formula drying plant in Hamilton. The fundamental understanding of the company and its processes has helped GEA take a highly innovative, tailored approach to the design of Dryer 2. Despite the challenges of a tailored design, the project was completed in under 12 months.

Process Overview

The DGC plant produces 2.3 tonnes of highly formulated infant formula, and 2.7 tonnes of formulated base powders and goat milk powder per hour.

The process includes milk reception from farms in New Zealand’s central North Island followed by heat treatment, separation and dosing of vegetable oils, powders, vitamins and minerals; concentration using falling film evaporators; spray drying; and packing into bulk bins and, once quality is assessed, packing into retail cans. The system also filters exhaust air to remove particles before releasing it into the environment. Throughout the process the system is designed to minimize power and water usage in line with the company’s sustainability objectives.

Innovating For Quality, Profit and the Environment

Dryer 2 at the Hamilton site includes a number of innovations tailored to DGC’s requirements:

Falling Film Evaporators

The multiple effect falling film evaporators are designed to handle batches of formula with elevated total solids which provides DGC with a saving in its annual energy costs it also means less energy is required from non-renewable energy sources with a resulting positive impact on the environment.

Computer Optimised Plant Design

GEA has modelled the drying processes within the dryer using Computational Fluid Dynamics running on its most powerful computers. This allowed the dryer shape and size to be optimised to require less frequent cleaning while still minimising the size and visual impact of the dryer tower building. Air supply to the dryer ensures even temperature and air flow distribution to improve dryer performance and minimise energy consumption.

Continuous Dryer Operation

Twin evaporators, each capable of a day’s operation prior to cleaning, cycle in turn to maintain a continuous feed to the dryer. In this way the dryer can be run continuously for many days before it too must eventually be stopped and cleaned. This is only the second infant formula dryer in the world to be set up for continuous dryer operation in this way. This technique improves dryer utilisation, increases powder output and reduces energy consumption. Less cleaning also reduces the consumption of resources such as energy and water.

Dryer Dehumidification

The customised desiccant dehumidifier continuously reduces and controls the humidity of the incoming air used for drying. This is the first time this type of technology has been used on a spray dryer in NZ. The dehumidifier allows the dryer to run closer to its optimum efficiency while maintaining capacity even during periods of higher ambient humidity and humidity fluctuations that would normally have a substantial impact on the performance of the dryer. One of the side benefits of dryer air dehumidification is that during the moisture adsorption process the air is heated by as much as 25°C for free.

Dryer Exhaust Air Recuperation

To improve energy efficiency and reduce waste heat losses a specially designed recuperation heat exchanger has been fitted by GEA to the exhaust stack to recover the energy from the exhaust air. This is the first such system installed on a dryer in NZ. The energy from the exhaust air is used to generate hot water. The hot water is then used during cold days to preheat the air used for drying, and on hot and humid days is used for regeneration of the desiccant dehumidifier system.

“We have had a very good relationship with DGC for a long time,” said Barry Cole, Business Development Engineer for GEA Process Engineering in New Zealand. “By working closely together we have been able to include innovations at the Hamilton site, many of which have not been seen before in New Zealand. We are all delighted with the outcome.”

“GEA has worked very collaboratively with DGC to design a flexible plant that meets the high standards required of an infant formula facility”. Brent Prankerd, General Manager Manufacturing for DGC also commented “We are pleased with the functionality and quality of the plant installed and the quality of the product being produced on the new drying facility.”

 

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Turnkey Distillation Project Services From Forsyths

Forsyths Ltd has had a long association with Chivas Brothers Ltd going back over 40 years, and previously with the Glenlivet Group for over 100 years.

During that time much renovation, rebuilding and expansion work has taken place at the various group distilleries. Most notably, the significant expansion of the Glenlivet Distillery five years ago and in 2013/14 the rebuilding of the old Imperial Distillery now renamed “Dalmunach Distillery” after the main water source.

Forsyths has grown significantly in the last twenty years, not only in the traditional Scotch whisky industry, but also in the design and build of Turnkey Distillery projects on a worldwide basis for the manufacturing of whisky, bourbon, rum, tequila, gin, vodka and of course malt whisky.

Forsyths in Rothes, MorayIronically Forsyths has worked at the old Imperial Distillery for over 50 years carrying out various repairs and replacements for the old owners, Scottish Malt Distillers (now Diageo). In the early 1990’s the distillery was extensively renovated by the new owners Allied Domecq, Forsyths was heavily involved in the restoration of copper work, boiler house, tankage and pipework throughout. This plant was again mothballed in 1998 and remained in that state even after the purchase of Allied Domecq by Pernod Ricard in 2005.

The site was always well suited for a distillery with a good water source and Forsyths was delighted to be involved when Chivas announced the building of a new distillery and commissioned Forsyths to build eight new Copper Pot Stills with all auxiliary equipment. These Forsyths designed and manufactured replicating the original shapes and contours of the old stills.

This beautiful new still house can produce 10 million litres of alcohol/year of good quality spirit.

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Arla Foods Ingredients Opens New €120 Million Factory

Arla Foods Ingredients has officially opened its new €120 million lactose manufacturing plant in Jutland, Denmark. The factory will produce 80,000 tonnes of lactose every year and is situated adjacent to Arla Foods Ingredients’ existing whey processing facility, Denmark Protein.

Lactose from the factory will predominantly be sold into the vibrant infant nutrition sector. Among the products made at the facility will be Arla Foods Ingredients’ premium ‘dry blend’ lactose, which enables infant formula manufacturers to increase their output dramatically without compromising safety or requiring significant capital investment.

ArlaFoodsIngredientsStaging2Luis Cubel, Sales Director for Arla Foods Ingredients’ Permeate & Lactose Business, says: “Our new lactose factory in Jutland is part of our drive to keep pace with growth in demand for high quality lactose in the infant nutrition sector. It is not just about serving our customers now, but also serving them in the future, with a consistent, reliable supply of lactose day in, day out.”

Henrik Andersen, CEO of Arla Foods Ingredients, adds: “The future direction of our business is about meeting demand in growth segments. Where it is necessary, we are not afraid to invest in the production facilities required to do that, as this modern facility demonstrates. Meeting demand for premium dairy ingredients is a fundamental pillar of our ‘Quality starts here’ brand platform, and we are dedicated to ensuring our customers can source the products they want at all times.”

Arla Foods Ingredients is a global leader in natural whey ingredients for products in a range of categories – from sports nutrition, beverages, bakery, dairy and ice cream to clinical and infant nutrition.

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PM Group Reports Strong Turnover and Profit Growth for 2013

PM Group, the international engineering and project management firm headquartered in Dublin, has reported turnover of €355.5 million for the year ended December 31st 2013, well ahead of prior year due to a significant increase in construction revenue. Operating profit before exceptional items was €7.2 million, a 26% increase on 2012. Pre-tax profits rose 20% to €9.7 million. Net assets at 31 December 2012 were €44.2 million.

Dave Murphy, Chief Executive Officer of PM Group, comments: “We’re very pleased to report a good performance for 2013, notwithstanding a moderate economic recovery in established markets and a slowing growth rate in emerging markets. We booked €110 million in new work orders in 2013 across the group and finished the year with a significantly stronger order book. That momentum has carried through to 2014 with current project activity ahead of last year.”

He adds: “We continue to invest heavily in our business across people, technology and innovation to drive the internationalisation of PM Group. Whether it’s a vaccine manufacturing facility in Belgium or a flavours facility in Shanghai, the technical and operational capability we deploy to design, construct and commission must be world class every time. Our team of over 2,000 people across Europe, Asia and North America continues to win business against the best in the sector, for which they deserve huge credit. This in turn has delivered a robust financial performance underpinned by a strong balance sheet.”

PM Group Chairman, Dan Flinter says: “We are now capitalising on the leading positions established worldwide in key sectors such as pharmaceuticals, food, med-tech and data centres. More than half our revenues were generated outside of Ireland in 2013, where we are increasingly using our international resources and capabilities to service existing global clients in the locations where they are investing.”

Dave Murphy concludes: “Revenue was ahead of target and well ahead of 2012, in Ireland and Western Europe due to our involvement in large scale pharma, food and data centre projects. Our UK operation has performed particularly well on the back of increased investment there in our core sectors and we also saw significant recovery in Central and Eastern Europe following a number of turbulent years. We had strong growth in our operations in Singapore and Shanghai and completed a number of large projects in India from our Bangalore office. Our East Coast West Coast presence in the US is also proving very beneficial in terms of developing client relationships and supporting offshore investments launched from the US.”

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PM Group Chairman Dan Flinter and CEO Dave Murphy.

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Production Commences at Chivas Brothers’ New Speyside Malt Whisky Distillery

Chivas Brothers, the Scotch whisky and premium gin business of Pernod Ricard, has completed the construction of its new Speyside malt whisky distillery, reinforcing its long term growth prospects in the face of increased global demand for Scotch whisky. The new distillery was commissioned by Chivas Brothers in 2012 with production commencing in October 2014.

Built using the latest innovations and environmental expertise such as heat recovery technology, the distillery is capable of producing up to 10 million litres of high quality Speyside style spirit per year to support the growing global demand for the bestselling blended whisky brands within Chivas Brothers’ portfolio, which includes Chivas Regal, Ballantine’s and Royal Salute.

The new distillery, which is Chivas Brothers’ 14th operating malt whisky distillery, is named Dalmunach after the nearby pool in the River Spey on whose banks the distillery sits. It has already had a positive impact on the local economy with companies from the Speyside area heavily involved in the construction, while an additional eight permanent employees have joined the Chivas Brothers production team.

ChivasBrosDalmunachDistillery2014Every element of the distillery design, including the unique still shapes, has been geared to producing the very highest quality Speyside malt whisky with a rich, fruity character, a vital ingredient to the highest quality blended Scotch whiskies.

Laurent Lacassagne, Chairman and CEO of Chivas Brothers, comments: “As global demand for Scotch whisky increases year on year, our confidence in the long-term growth prospects for the category remains strong. The construction of the new Dalmunach distillery is a clear demonstration of our confidence and also of our commitment to invest to meet the significant growth potential.

He adds: “With their reputation for crafted excellence, our blended whiskies form a key part of the Chivas Brothers portfolio in both emerging economies and mature markets, so we believe the increased capacity which the new distillery will provide will help to drive the business forward in the years to come.”

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$50 Million Investment in Mondelez’s Hungarian Chocolate Plant

The European business of Mondelēz International has invested $50 million (HUF11 billion) over the past three years in the development of the Székesfehérvár chocolate plant at one of its group members, Győri Keksz. Three new production lines have been installed producing Milka and Cadbury choco-bakery sandwiches exclusively in this plant, mostly for export but more recently for the Hungarian market as well. The investment financed fully by company funds created more than 350 new jobs in the region.

Thanks to the investment, real power brands have now moved into the facility. The choco-bakery sandwich products of Milka and Cadbury with TUC, LU and Ritz biscuits are now all produced in this plant – these products have become huge successes for the snacking giant since their launch. In order to meet increasing market demand, the company has not only installed three new lines but also extended the production area with a new chocolate silo and a packaging and raw materials warehouse. The new investment realized in three phases has increased production capacity by 70% and created more than 350 new jobs in the region.

“Mondelēz International is investing big to ensure that its power brands are manufactured on state-of-the-art equipment. Our company invested more than $1 billion worldwide in our supply chain capacities since 2012 and we have plans to do even more. Our Székesfehérvár investment put this plant on the confectionery map of Europe. We are committed to realizing its full potential to create delicious moments of joy for our consumers,” says Philip A Hodges, Senior Vice President, Integrated Supply Chain, Mondelez Europe.

Mondelēz International’s Hungarian subsidiary has been operating in Hungary for twenty years. Its product portfolio encompasses popular brands like Milka, Sport szelet, Győri Édes, JóReggelt!, Dörmi, TUC, Halls and Negro.

The company has two production facilities in Hungary – the Győr plant at Győri Keksz Kft., produces Negro health drops and Halls candies while the Székesfehérvár plant produces real world brands, like the innovative chocolate-and-biscuit sandwiches of Milka and Cadbury and the TUC and OREO biscuits, besides popular heritage brands (Győri édes, Pilóta).

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Diageo Invests €169 Million to Regenerate Historic Guinness Brewery

Diageo has officially opened its new Eur169 million brewing centre of excellence at its historic St James’s Gate site in Dublin, where all Irish beer production has now been consolidated. With current annual output of about 7 million hectolitres of beer, the modernised St James’s Gate Brewery is core to supporting the growth and development of Diageo’s global beer business and its flagship Guinness stout brand.

The rejuvenation programme at the St James’s Gate Brewery has entailed the creation of a new brewhouse, the construction of a new grain intake building and associated silos, an extension of the existing fermentation plant to the southwest of the new brewery and the associated expansion of utilities generation and distribution. About 40% of the total investment was spent on the new brewing facilities and about 35% on new fermentation vessels to handle the additional capacity.

The new state-of-the-art brewhouse incorporates three brew streams with a total capacity of 8 million hectolitres per annum. It is the world’s largest stout brewhouse, capable of producing 300,000 pints in every two hour brew.

The brewhouse building will also house a Guinness Flavour Essence plant to produce concentrate for the brewing of Guinness in over 50 countries across the globe. This concentrate, the basis of which is roasted barley, is used to impart the distinctive colour and flavour of Guinness in overseas markets where the brand is produced locally.

The overall brewery output is currently 7 million hectolitres of beer annually, the new brewhouse has expanded the capacity of the St James’s Gate site by about 40%. Guinness stout is the main product, with about 5 million hectolitres due to be produced annually along with 1.5 million hectolitres of lager and 0.5 million hectolitres of ale. In addition to Guinness, the enlarged Dublin brewery also produces Carlsberg, Budweiser, Harp and Satzenbrau lagers along with Smithwick’s and Kilkenny ales. Some 70% of the brewery’s output is exported.

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Tullamore Distillery Nears Completion as Spirit Safe Installed

The long-awaited return of Irish whiskey production to the town of Tullamore has moved a significant step closer with the installation of the custom-made Tullamore Distillery Spirit Safe. The symbolic and functional heart of a distillery, the installation of the Spirit Safe is a major milestone in bringing Tullamore D.E.W. production back to its hometown. The first spirit will flow from the new €35 million distillery in mid-September exactly 60 years after the closure of the original distillery.

Tullamore D.E.W. is the world’s second largest Irish whiskey brand and has seen global sales double to more than 850,000 (9L) cases since 2005. The brand is owned by independent family-owned Scotch whisky distiller William Grant & Sons.

As part of the distillation process, the Master Distiller applies their skill and specialist knowledge through the spirit safe to identify the middle cut, or ‘heart’ of the spirit before filling it into casks for maturation. It allows the spirit to be fully analysed by the distiller without compromising the integrity of the distilling process. Only the finest ‘cut’ of the spirit is used, with the first and the last cut, referred to as the ‘top and tail’, retained and added to the next distillation.

Tullamore Distillery’s Spirit Safe which was made by the famous Forsyth Group from the town of Rothes in Moray, Scotland completed the 775 km journey to Tullamore under the care of two of Forsyth’s specialist engineers who expertly installed it at the heart of the still house. The 10 cu m glass and polished brass Spirit Safe is uniquely designed in a triangular shape, an appropriate reference to Tullamore D.E.W.’s complex triple-distilled, triple blend of all three types of Irish whiskey, while also paying tribute to the Grant family’s coat of arms which features its own trio of crowns.

The introduction of the spirit safe dates back to 1823 when duty laws were brought in to enforce taxation on distilleries. For this reason spirit safes feature a large elaborate padlock which casts back to a time when only an Exciseman, who enforced tax collection, could unlock the safe to access the spirit. Despite technological advances in distilleries the Spirit Safe stills plays an important role in modern whiskey making.

Denise Devenny, Tullamore Distillery Process Leader, comments: “The Spirit Safe is the most important element in the distillation process and is used to select the finest cut of spirits. There is no better sight than seeing pure spirit washing around the mouth of the collection bowl and disappearing to be matured in casks knowing that it will only re-appear many years later to be enjoyed by generations of whiskey connoisseurs.”

The annual production of the new distillery will be 1.84 Mla of triple distilled pot still and malt whiskeys – the equivalent of about 1.5 m cases.

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Vion Invests in Bavarian Meat Plants

Vion Food is to make a multi-million euro investment in its Bavarian processing plants as part of a new strategy for its German operations. Almost half of the investments will focus on the expansion of the slaughter- and cutting plant in Landshut, Bavaria. Completion of the project in mid-2015 will see processing capacity almost double to 21,000 pigs per week.

In Vilshofen, another specialist pork slaughterhouse in Bavaria, millions more will be invested to install state-of-the-art equipment, that will optimize processing efficiencies. Vion assumes that the parties of the minority shareholder, producer association Südostbayern eG, will also approve the investments in Landshut and Vilshofen.

Landshut and Vilshofen are key regional pork businesses for Vion and are important for the export market. At the same time, Vion is to invest in the Waldkraiburg plant in Upper Bavaria. This will become the largest beef plant within Vion, with capacity increasing from 3,000 to 4,500 cattle per week.

Pig processing will focus on the Landshut and Vilshofen sites and the Waldkraiburg plant will become the largest beef plant. As a result, it is envisaged that in the long-term, the business locations at Straubing and Pfarrkirchen will close. It is also planned to close the beef processing plant at Leutkirch, with cattle being re-directed to the Buchloe and Crailsheim operations.

Netherland-baed Vion Food had a turnover of €7 billion in 2013 and is by one agricultural stakeholder, the Zuidelijke Land- en Tuinbouworganisatie (ZLTO), with approximately 16,500 members.

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Clegg Food Projects Completes Scheme for 2 Sisters Food Group

Clegg Food Projects has completed its latest scheme for its client food manufacturing giant, 2 Sisters Food Group. The project has seen the extension and alteration of an existing factory in Cambuslang, Glasgow and continues Clegg Food Projects’ portfolio of work for 2 Sisters Food Group over the last 3-4 years.

“We’ve worked with 2 Sisters Food Group on several projects previously and we are thrilled to have secured this scheme with them,” says John Moxon (pictured), business development director at Clegg Food Projects. “It is always satisfying to receive repeat business from a client and shows that Clegg Food Projects always delivers to a very high standard.”

The 11,000sq ft extension to the factory’s plant will house two modern high volume ovens, spiral chillers and freezers, plus a general refurbishment of the current site.

Clegg Food Projects started on site last year in Westburn Farm Road. The build will create up to 180 jobs and accommodate up to 50 per cent additional capacity at the site.

Clegg Food Projects provides solutions for major food operations all over the country, including design, engineering, specialist construction and consultancy. For more information about Clegg Food Projects, visit www.cleggfoodprojects.co.uk.

 

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Edrington Group Receives Planning Approval For New £100 Million Distillery

Scottish spirits producer Edrington Group has been granted planning permission by the Moray Council for a new £100 million iconic distillery and visitor centre in Speyside for The Macallan brand. Works will now progress on the delivery of the new facility which is scheduled to open to the public in Spring 2017. The Macallan is one of Edrington’s core brands.

Edrington has appointed Robertson as preferred contractor for the new facility, and Forsyths of Rothes as supplier of the distillation equipment.

Graham Hutcheon, Group Operations Director of Edrington, says: “Only the external appearance of the distillery will change, the exceptional quality of The Macallan, which has been produced for many years using copper stills from Forsyths, will not be compromised and the same focus on attention to detail and personal care of the whisky’s production will be upheld. The new distillery will undoubtedly become one of the most talked about distilleries, not only in Speyside but globally, and we look forward to starting on site soon.”

In addition to creating a site of major architectural significance, the new distillery will ensure the on-going quality control of the production of The Macallan, both of which further consolidate The Macallan’s position as one of the world’s leading luxury spirits. Over time the distillery will deliver additional capacity to meet the growing demand from existing and new international markets.

With its rolling roofscape, the distillery has been designed to complement the natural beauty of the area and The Macallan Estate, which overlooks the River Spey.

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Sidel creates new drinks bottling business unit

PET solutions provider Sidel has created a new business unit to serve drinks products producers globally.

Split into six teams including maintenance, line improvement, training, spare parts and logistics, line conversions and moulds and packaging, Sidel Services has been designed to help customers achieve better product quality, efficiency, flexibility, cost optimisation and brand support.

Sidel CEO and president Mart Tiismann said that when customers invest in a Sidel production line, they need and expect high levels of service to support them throughout the entire working life of the equipment.

“That is why, in addition to introducing innovative technologies to our customers such as the Sidel Matrix™ liquid packaging system, we have also been working hard to improve our services offering,” he said.

Companies can use the new service unit to reduce downtime or design new packaging solutions. Sidel is also rolling out new spare parts logistics and technical support initiatives in a bid to help customers have better access to the people and parts that they need.

The improved global logistics network for spare parts includes a new warehouse management system that enables three levels of delivery service, from emergency delivery to planned maintenance deliveries.

According to the company, the technical support system enables faster responses through a new ticketing system that places customers in immediate contact with Sidel experts to address urgent issues.

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Finsbury Food Group Doubles Capital Investment Spend

Finsbury Food Group, the UK manufacturer of cake and bread bakery goods, has taken advantage of its strong balance sheet to double capital investment spend to over £6 million in the year ended 28 June 2014 to underpin future growth via new capacity and innovation whilst also improving productivity and competitiveness. Within the group’s UK Bakery division, cake capital investment projects successfully completed in the year include the new single serve cake slice ‘snap pack’ line as well as the largest cake bites robotic picking installation in the world. The Nicolas and Harris speciality bread facility expansion, delivering 60% additional space, has also been successfully commissioned and is now fully operational.

John Duffy, chief executive of Finsbury Food Group, comments: “Our continued capital investment programme is heralding positive signs and we are encouraged by the contribution that this has made. Although cost inflation keeps margins under pressure, the strategies we have in place have mitigated against this and with more favourable profit dynamics; we are well placed to take advantage of the market as it improves.”

The Finsbury board expects to report full year profit up on the prior year and ahead of market expectations. Following the sale of the Free From business in February 2013, continuing full year group sales revenues for the year ended 28 June 2014 are £175.7 million, against £176.6 million in the previous year. Second half growth in the UK Bakery business reversed the first half decline and sales for the year were broadly flat at £153.7m. Sales in Lightbody Europe, the group’s 50% owned European business declined by 1.2% for the full year to £22.0 million, however this sales decline is accompanied by a favourable profit dynamic with a shift to higher margin business.

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Heineken to Invest £108 Million in UK Production Sites

Heineken is to invest £50 million in its Manchester Brewery in addition to the £58 million already announced for its cider plant at Hereford; in order to modernise the facilities and expand the capacity at both sites. A further £18 million will be invested in upgrading and modernising Heineken UK’s Star Pubs & Bars estate.

This investment will ensure that Heineken’s UK production facilities remain at the forefront of industry standards to help meet continued demand for its strong portfolio of ciders and beers.

Heineken is the UK’s leading cider and beer producer with a strong brands portfolio including Strongbow, Bulmers, Heineken, Foster’s, Kronenbourg 1664 and Desperados, together with a full range of speciality brands.

Heineken UK employs around 2,000 people across eight sites. It has breweries, cider plants and offices in Edinburgh, Livingston, Tadcaster, Manchester, London, Hereford and Ledbury.

Star Pubs & Bars is Heineken’s leased pub business which is made up of an estate of around 1,250 pubs throughout the UK.

Heineken Manchester is the world’s biggest brewer of Foster’s as well as home to Kronenbourg 1664 in the UK. Heineken is spending £50 million to increase brewing production by approximately 2 million hectolitres per annum (around 350 million pints); and on a new kegging line which will provide pubs with quality draught beer. The Manchester Brewery is a strategic production site within its UK brewing network, and the investment will enable Heineken to continue to meet strong customer demand for is brands into the future. The Manchester brewery investment will secure 240 jobs, and work will be completed in the summer of 2015

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Heineken to invest £126m in UK

Heineken is to invest £126 million into expanding its UK operations; £50m at its Manchester brewery, £58m at its Hereford Cider plant and a further £18m on upgrading its UK pubs.

The brewer said the investment at its Hereford plant would create a world class cider production facility capable of supporting Heineken’s growth in the cider market and allow it to scale up exports, while securing 270 jobs, with work set to complete in 2016.

Production capacity at Heineken’s Manchester Brewery will be increased to two million hectolitres per annum (around 350 million pints) thanks to an investment of £50m, creating 240 jobs, with work set to complete by the summer of 2015.

David Forde, UK managing director of Heineken, said: “Heineken is the UK’s leading beer & cider business, a position that we are proud of and determined to build upon. These major investments are a clear demonstration of our long-term commitment to the UK.

“Heineken is committed to the UK marketplace and investing in the right infrastructure to ensure that we can continue to delight our consumers day-in and day-out with fantastic cider and beer experiences.”

A further £18.5m will be spent on upgrading the company’s 1,250 Star Pubs & Bars, which includes 60 to 70 major refurbishments as well as more than 100 external signage and redecoration schemes.

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Molson Coors Brewing to Make Further Investment in Britain’s Biggest Brewery

As part of its five year Burton Brewery redevelopment plan, Molson Coors, Britain’s biggest brewer, has announced a further investment of £28 million in brewing technology and infrastructure. The investment takes the total now invested in the facility to £75 million and is the biggest single capital investment in British brewing over recent decades.

Part of the investment programme includes £21 million state of the art bottling line that offers Molson Coors greater capability to meet the on-going needs of its consumers through bottle and pack innovation.

The newly announced investment will support brewing a large proportion of the 1.2 billion pints of beer brewed at Molson Coors’ Burton Brewery. The modern brewing technology will maintain the brewer’s high quality standards to ensure UK favourites, such as Carling, Coors Light and Cobra continue to delight future generations of beer drinkers.

Simon Cox, managing director of Molson Coors UK & Ireland.

Simon Cox, managing director of Molson Coors UK & Ireland, says: “We are excited to be investing further in Burton Brewery and its workforce as we continue our redevelopment programme. Funded by the biggest investment in our industry for decades, the new infrastructure and technology at the brewery will maintain our rich heritage of brewing in Burton.”

The new buildings and technology, including a new energy centre, will also help Molson Coors to achieve its target of reducing energy use by 25 percent and cut 20 percent of its greenhouse gas use by 2020 as outlined in the company’s 2013 Corporate Responsibility Report.

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Laita to Invest €80 Million to Expand Capacity

French dairy co-operative Laïta has unveiled an €80 million investment programme to expand its production capacity in dry dairy ingredients.

The two year development plan involves the installation of new industrial equipment at Laïta sites in Finistère, Côtes d’ Armor and Loire-Atlantique. By 2017, the new equipment will enable:Laita to produce an additional 30,000 tonnes of canned infant milk powders and premium milk powders annually, as well as 7,500 tonnes of demineralised whey.

Overall, the investment will expand Laïta’s milk processing capacity by 15%.

Founded in 2009, Laïta is an umbrella organisation representing the dairy activities of the Even, Terrena and Triskalia co-operatives in north-west France, and is one of Europe’s ten leading dairy co-operatives.

The investment plan is at the heart of the co-operative’s mission: to provide sustainable opportunities for production at the 3,750 farms that supply Laïta with milk and to contribute to the long-term development of the region.

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Green Isle Foods to Invest €30 Million in its Irish Operations

Green Isle Foods, the leading Irish frozen foods company, is to invest €30 million across its operations in Ireland which will result in an additional 115 jobs over the next five years. As a result of the investment, which is intended to position Green Isle Foods for future growth in Ireland and overseas, an additional 50 jobs will be created at the company’s pizza production facility in Longford and an additional 65 jobs in its pastry production plant in Portumna.

The investment also secures the jobs of the 700 people currently employed by Green Isle. The investment programme is being supported by the Department of Jobs, Enterprise and Innovation through Enterprise Ireland.

Green Isle Foods is part of the UK-based 2 Sisters Food Group, which has a total turnover of £3 billion with approximately 24,000 employees worldwide. The company operates in some of the most dynamic and fast moving categories of the food industry and represents household brand names such as Green Isle, Donegal Catch and Goodfella’s.

Eddie Power, managing director of Green Isle Foods, says: “Green Isle Foods is a company of ambition operating in what are exceptionally competitive markets. It is critical that we have well invested facilities to ensure that we compete and win on both national and international stages. This investment programme increases our capacity and extends our product offering and secures access to a wider range of international markets.”

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Valio Building €170 Million Snacks Plant

Fiinsih dairy group Valio is to commence the construction of a new snacks plant in Riihimaki, near its existing Valio Herajoki plant. The value of the investment in the building is around Eur75 million and the total budget for the snacks plant amounts to around Eur170 million. Valio is also to invest Eur2.5 million in increasing cottage cheese capacity at the company’s Seinäjoki plant.

In the first phase, Valio will build a plant with a floor area of around 18 000 square metres on a plot of land purchased last year, enabling the environmentally sound, efficient and flexible production of snacks. The earthworks for the construction project will start immediately and the plant is slated for completion by the end of 2016. The plant itself will create dozens of new jobs in production and warehousing operations.

Valio’s present dairy in Riihimäki is 45 years old and will continue liquid milk production after the new plant has been completed. Valio fresh dairy products are enjoyed in neighbouring markets as well as Finland.

Sales of Valio products, especially milks and yoghurts manufactured in Finland, have increased markedly in Russia and Sweden in recent years. The demand for value added products, such as Eila® items, yoghurts and high protein products is expected to continue to grow.

In Sweden, Valio’s largest product groups are yoghurts and Valio Eila®. In Russia, growth stems primarily from fresh dairy products, while Oltermanni® cheese and Valio butter also sell in large volumes and contribute significantly. In bothRussiaandSweden, net sales expressed in euros increased by more than 10% in 2013.

In Sweden, Valio’s Eila® brand has captured over 55% of the lactose free products market.

“The new plant will enable us to expand our snack products range in Sweden further. We need to be nimble and responsive, especially in the rapidly growing lactose free yoghurt segment,” says Iiro Wester, Managing Director of Valio’s Swedish subsidiary. In Russia, fresh dairy products have been the fastest growing category of our exports to the country in recent years.”

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Mondelez International to Expand Chocolate Crumb Capacity

Mondelez International is investing €5 million to expand its Irish chocolate crumb manufacturing plant at Rathmore in County Kerry. The investment programme, which includes the installation of a new milk evaporator, is designed to improve competitiveness by reducing energy costs and the environmental impact of the plant. Subject to planning permission, work is expected to commence in May 2014 and be completed by August 2015 when commissioning will take place.

“Rathmore has a proud manufacturing heritage and we are committed to ensuring it continues,” says Head of Manufacturing, Ian O’Toole. “This proposed investment demonstrates confidence in our manufacturing capability. This enhanced technology forms part of an overall Mondelez manufacturing strategy to drive efficiency in manufacturing processes and ways of working. The investment represents an important stepping stone for Rathmore’s competitiveness journey.”

Currently employing 86 people and sourcing about 80 million litres of fresh Irish milk annually, the factory was established in 1948. The chocolate crumb is used in the manufacturing of chocolate confectionery at the Mondelez factory at Coolock in Dublin, and is also exported to the US, Canada and the UK. Mondelez gained the Rathmore and Coolock facilities following its acquisition of Cadbury for $19.5 billion in 2010.

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Greencore to Develop £20 Million Greenfield Factory in the US

UK convenience food manufacturer Greencore Group is to build agreenfieldsandwich manufacturing facility in Quonset, Rhode Island in the USA. The new facility will be strategically located to enable Greencore USA both to service its existing markets in New England and also to develop future business opportunities closer to New York.

As a result of the project, the group will close its existing facilities in Newburyport and Brockton, Massachusetts on a phased basis between April and September 2015. Employees will be offered the opportunity to take up roles at the new facility.

The site will be over 100,000 sq ft with a modular design that will enable future expansion, and will be built to the highest standards of hygiene, efficiency and process capability. It will have sufficient capacity to support ongoing growth and will also result in material manufacturing process and distribution savings estimated at £5 million. The new site will employ 370 people when it opens in the Spring of 2015.

The cost of construction and fit-out of the new facility is estimated at £20 million and will be incurred over the next 15 months. Greencore will also recognise a non-cash impairment of assets in FY14 of £8 million in relation to the exit from the Newburyport and Brockton sites, as well as cash exit and start-up costs estimated at £3 million. These costs will be reported as exceptional items.

Patrick Coveney, chief executive of Greencore, comments: “This investment will significantly enhance our capability and capacity to serve the sandwich market in the North Eastern region of the US, and will also enable us to drive further growth with current customers. Delivering this project will represent an important milestone as we continue to build a strong, growing, profitable food to go business in the USA.”

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Tullamore D.E.W. Marks Major Milestone

Irish whiskey brand Tullamore D.E.W. celebrated St Patrick’s Day 2014 with the arrival of four hand crafted copper stills, in preparation for the landmark opening of its new distillery in Tullamore in the heart of Ireland. This is the first public glimpse inside the distillery building and marks a major milestone in Tullamore’s history by bringing Tullamore D.E.W. whiskey production back to its roots after 60 years.

The copper pot stills are the heart of a whiskey distillery and play a vital role in creating Irish whiskey’s distinctive taste. Forged by the famous Forsyths Coppersmiths in the town of Rothes, the imposing stills were painstakingly hand crafted to replicate the originals, which were in use at the old Tullamore distillery until its closure in 1954. The custom-designed copper stills travelled 775 km in six separate pieces across the Irish Sea from Northern Scotland, before being riveted and welded together on arrival at the distillery in Tullamore, County Offaly.

Stella David, chief executive of independent distiller William Grant & Sons, which owns the Tullamore D.E.W. brand, comments: “The arrival of the stills marks another step towards the return of the whiskey making tradition to Tullamore. We are excited to be marking this momentous event in a journey that has been almost 3 generations in the making.”

The rapid international growth of Tullamore D.E.W. sales worldwide has played a role in reviving Irish whiskey into the world’s fastest-growing spirit. As the second largest Irish whiskey brand in the world, with global growth of around 10% per year, Tullamore D.E.W. is a key contributor to the growth ofIreland’s exports.

Worldwide sales of Tullamore D.E.W. have doubled to almost 850,000 (9L) cases since 2005. With construction now well under way, the distillery ensures that family owned distiller William Grant & Sons can cope with demand as the brand continues to grow globally in the USA, Germany, Sweden and Central and Eastern Europe where Tullamore D.E.W is already a leading player. The annual production of the new distillery will be 1.84Mla of triple distilled pot still and malt whiskeys – the equivalent of about 1.5m cases.

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Speyburn Distillery Unveils £4 Million Expansion Programme

Speyburn Distillery is to undergo a £4 million expansion to double production capacity in response to the rising demand for Scotch whisky globally. The development programme is due to be completed by the end of 2014.

Speyburn is part of the Inver House Distillers portfolio, which is owned by International Beverage Holdings. The distillery investment will increase Speyburn’s production capacity from 1.8 million litres to over 4 million litres each year, allowing the business to lay down stock for predicted future growth in both established and emerging markets – with the brand’s volume growth forecast at 15 per cent for the 2013/2014 period.

The expansion design will significantly reduce the distillery’s energy consumption per litre of alcohol and improve its carbon footprint, with predicted energy savings of more than 20 percent once the extended distillery is up and running. This will be achieved by using the most up-to-date and energy efficient distillation equipment – whilst maintaining the distillery’s traditional methods of production. The expansion will also provide a boost for local businesses, with Rothes-based whisky specialists Forsyths contracted to manufacture all new production equipment and Elgin-based construction company Robertson also undertaking elements of the project.

Often described as one of the nation’s most photographed distilleries, Speyburn Distillery was founded in 1897 and produces Speyburn Highland Single Malt Scotch Whisky, which is already a top 10 malt brand in the USA – the biggest Scotch single malt market in the world.

Inver House Distillers’ Managing Director Graham Stevenson comments: “As we continue to be very optimistic about the long term potential for Scotch whisky, particularly in the emerging BRIC, African and South East Asian economies, investment in our production capabilities is crucial. Having the infrastructure in place to produce our high quality whiskies in greater quantities will be key to the future success of our brands, so we are delighted to see the first phase of this major programme of work get underway at Speyburn Distillery.”

Established in 2006, as the international arm of ThaiBev, International Beverage Holdings specialises in developing distinctive, premium local brands for global growth, with a portfolio that is led by a range of high quality Scotch whiskies and includes some of the fastest growing beers, spirits and whiskies on the market today.

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Mondelez International to Invest $130 Million in US Biscuit Manufacturing

Mondelez International is taking another important step in creating a best-in-class global supply chain by investing more than $130 million in new biscuit manufacturing technology and capabilities in its current US network. The investment will focus on bakeries in Fair Lawn, NJ, and Richmond, Va, supporting priority cookie and cracker brands and product platforms. To enable this investment, the company will consolidate its current US biscuit manufacturing footprint on the East Coast, resulting in the closure of its Philadelphia bakery by early 2015.

“This investment in our North American biscuit supply chain offers us an exciting opportunity to further improve the overall effectiveness, efficiency and the competitiveness of our manufacturing network, with a focus on driving big bets and accelerating growth for the biscuit category,” says Cindy Waggoner, Vice President, North America Integrated Supply Chain, Biscuits. “This announcement is also bittersweet. It’s always a difficult decision to close a manufacturing facility, especially one like the Philadelphia bakery, which has been part of our organization and the community for many years.”

The role of the Philadelphia bakery within the company’s biscuit manufacturing network footprint has changed over time. The site currently produces a limited number of core products. Other facilities are better positioned to support the company’s future business needs.

The closure of the Philadelphia bakery will affect approximately 350 employees.

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Major Investment to Boost Arla’s Profitability

Arla Foods is looking to expand its production globally and make it more eco-friendly by investing DKr2.2 billion (Eur295 million) in ten of its dairy sites in 2014. The focus will be on production of profitable export products for the company’s strategic growth markets outside the EU.

With an ambition to double its exports of European dairy products to growth markets outside the EU by 2017, Arla has announced a new investment plan for the coming year. Recently approved by the board of directors, the plan contains investments of up to DKr2.2 billion.

Povl Krogsgaard.

The money will go into new and ongoing dairy expansions and into projects that will help make Arla’s production even more climate-friendly.

“This year we are increasing our investments to dairy sites that contribute to our export out of Europe. Our sales on the growth markets outside the EU are growing at a fast pace, and we must prepare ourselves to meet the rapidly growing demand in years to come. In Arla we are determined to create good growth, and we are therefore also investing more than DKr125 million in projects that will make our production chain even more climate-friendly,” says Vice-CEO in Arla Foods, Povl Krogsgaard.

In total, DKr750 million will be invested in production for Arla’s strategic growth markets outside the EU – Russia, China, the Middle East & Africa – which is a third of this year’s production investments (compared to DKr466 million in 2013).

Arla’s production investments in 2014 make up nearly three per cent of the expected turnover of approximately DKr79 billion, which is also the ambition in Arla’s Strategy 2017. The goal is to increase profitability in Arla’s business and thereby create a higher earning for Arla’s cooperative members long-term.

The largest single investment in 2014 is approximately DKr530 million for the ongoing construction of a new lactose production site near Nr. Vium in Denmark. The new site will produce value-added lactose ingredients based on whey from Arla’s nearby cheese production. These ingredients will be used for child nutrition products and other categories and sold to the food industry globally by Arla’s subsidiary Arla Foods Ingredients.

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Plans For New €10 Million Whiskey Distillery in Dublin

The Teeling Whiskey Company has announced plans for a new Irish whiskey distillery to be located at Newmarket Square in The Liberties area of Dublin. This will be the first new distillery in Dublin in over 125 years and brings the Teelings home to their ancestral roots.

The Teeling Whiskey Distillery is due to start production in the fourth quarter of 2014 with the visitor centre opening its doors in early 2015. The €10 million project will lead to the creation of at least 30 full-time jobs. The distillery will also see 50 jobs created in the construction phase.

The Teeling Whiskey brand is already on sale in Ireland and over 18 export markets. The construction of the new distillery will guarantee future supply for the Teeling Whiskey brands and allow the creation of a range of innovative and authentic Irish whiskeys based on the traditional and unique Dublin style of distillation. The proposed new pot still distillery will have the capacity to produce 500,000 litres of whiskey on an annual basis and will consist of three traditional copper pot stills reviving the traditional style of the old Dublin distilleries.

Jack Teeling (pictured), founder and managing director of the Teeling Whiskey Company, comments; “This project will bring distilling back to an area of Dublin long associated with world class whiskey which at one stage had 37 different operational distilleries. Building a working distillery is just one part of our plan for the Newmarket site which will also involve the development of an integrated visitor experience to showcase the rich distilling history of Dublin and in particular The Liberties. Dublin whiskey was at the forefront of the last golden age of Irish whiskey. We aim to revive the ‘spirit of Dublin’ by putting Dublin and Teeling Whiskey firmly back on the map again.”

He adds: “It is unquestionable that there has been significant growth in the Irish whiskey market worldwide, particularly in the US, and we want to be the leaders in creating a bright new future for Irish and Dublin whiskey. The new distillery will guarantee future supply and ensure we control the distilling process from grain to bottle, whilst also giving consumers the opportunity to further interact with the brand, as we revive the old tradition of whiskey distilling in The Liberties.”

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Mondelez International to Invest £75 Million at Bournville Site

Mondelez International is to invest £75 million on upgrading the Cadbury factory and headquarters at Bournville near Birminghamin the UK. The money will be spent over three years and will entail the installation of new production lines and new equipment, leading to greater job security. The Bournville factory currently employs about 1,000 people and produces some of the firm’s most popular chocolate, including Dairy Milk, Creme Eggs and Wispas.

According to Mondelez International, the investment will focus on improving capabilities, reducing costs and changes to ways of working that will help to close the competitiveness gap between Bournville and its competitors as well as sister factories in Germanyand Western Europe.

“Bournville has a proud manufacturing heritage and we are committed to ensuring it continues and becomes a world class manufacturing site. This investment would secure the site’s future for the next generation,” says Neil Chapman, manufacturing director of Chocolate UK for Mondelez International. “The competitiveness gap we have identified means we are already missing out on important opportunities to grow.”

Since acquiring Cadbury in 2010, Mondelez International (formerly Kraft Foods), has invested more than £130 million in its UK operations. Bournville is home to the company’s Global Centre of Excellence for Chocolate research and development site, so every new chocolate product created by the company anywhere in the world starts life at the Birmingham plant.

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New Milestone in Diageo Scotch Investment

Diageo has announced plans for a £30 million expansion of its Clynelish Distillery in Sutherland, Scotland. In the latest major milestone in Diageo’s £1 billion programme to increase Scotch whisky production, plans have been submitted to Highland Council for the major expansion of Diageo’s most northerly Scotch whisky distillery.

The Clynelish expansion will take the on-going capital investment by Diageo in the Highland Council region alone to almost £150 million, including major expansions at Glen Ord and Teaninich Distilleries and plans to build a new distillery at Alness.

Keith Miller, Diageo director of Distillation and Maturation, says: “The plan to expand Clynelish Distillery is another major milestone in Diageo’s £1 billion investment to increase Scotch whisky production capacity to help meet the future growth in global demand for our brands. Clynelish is a very special distillery, producing spirit which is highly prized for its quality and character and is an important part of our Scotch whisky blending inventory, so this is an important part of our investment programme.”

He adds: “I’m particularly pleased at the investment we are making in the Highland region. From Muir of Ord to Brora the investment in our distilleries is now almost £150 million, which we believe is bringing great benefit to the local economies and communities.”

The Clynelish announcement came as six new copper stills were delivered to the Glen Ord Distillery as part of the £25 million expansion plan which is doubling the size of that distillery to over 10 million litres per annum. Diageo is also doubling the capacity at the Teaninich Distillery in Alness and is progressing plans to build a new malt whisky distillery and renewable energy plant on land adjacent to Teaninich. In total these projects represent a capital investment of nearly £150 million across the Highland Council area.

Clynelish Distillery produces single malt whisky unique in both taste and texture which is highly prized by Diageo’s master blenders for use in world-leading Scotch whisky brands such as Johnnie Walker. Clynelish is also a highly regarded as a single malt whisky in its own right. The distillery is also home to one of Diageo’s 12 distillery visitor centres, welcoming more than 5,000 visitors each year. Clynelish is near the Sutherland town of Brora.

Under the plans submitted Clynelish Distillery will see the installation of an additional mashtun (the vessel for soaking the malted barley) 10 new washbacks (vessels for the fermentation process) and six new copper stills for distilling the spirit. This adds to the 10 washbacks and six stills which the distillery currently has and will effectively double the production capacity to nine million litres of alcohol per annum, whilst retaining the unique character and quality of the spirit. A bio-energy plant is also planned for the site to provide non-fossil fuel energy to power the distillery.

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Premier Foods to Invest £20 Million at Barnsley Site

Following the ongoing success of Mr Kipling cake slices, Premier Foods is to invest £20 million in building a new production and packing line at its cake manufacturing site in Fish Dam Lane in Carlton, Barnsley. The new line will be capable of producing a staggering 300 million cake slices a year, doubling the company’s current capacity, to meet growing consumer demand for its Snack Pack format of individually wrapped slices.

Mr. Kipling Snack Packs, available in six different flavours, were introduced in 2011 to provide a convenient, on-the-go format suitable for lunchboxes and in-home eating occasions that have since proved a runaway success.

The investment will take 12 months to complete and involves the installation of a mixing station, oven and sophisticated packing robotics adding significant volume to the site.

Jason Ramsay, factory general manager for the Carlton site, says: “This investment is a strong vote of confidence by Premier Foods in the Carlton site and the Carlton workforce. We have been manufacturing Mr. Kipling cake at Carlton since 1975 and this latest news is a huge boost for all of us.”

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Multi-million Investment by First Milk at Haverfordwest Creamery

First Milk, the British farmer owned food business, has just commenced two major investment projects at its Haverfordwest Creamery in Pembrokeshire. Wales. Nearly £7 million is being invested in a brand new effluent treatment plant and the installation of new boilers which run on clean burn natural gas.

These projects come on top of a £9 million of investment in recent years which has made Haverfordwest Creamery one of the very best in the dairy industry.

The investment in new gas boilers, which are replacing the current heavy fuel oil units, will reduce carbon emissions at the site by a massive 3,500 tonnes per year, equivalent to taking 2,000 cars off the road. As part of planning for the effluent treatment plant, First Milk developed a unique partnership with Natural Resources Wales, which targets reducing not only the environmental footprint of the creamery, but also a large group of farms that supply it.

Finally, further investments at the creamery are currently being scoped out for 2014 and 2015. Part of these plans will involve increasing capacity at the site to meet growing demand for its cheeses. As part of this investment drive, the company is actively recruiting for more milk in West Wales and has a new contract in place that is paying one of the highest milk prices in the UK.

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Glanbia to Create 90 Jobs in Ireland

Glanbia plc, the global performance nutrition and ingredients group, has announces two new investments inIreland, which will create 90 jobs in Monaghan and Dublin.

Glanbia Consumer Products, owner of the Avonmore and Premier brands, will build a new UHT (Ultra-Heat-Treated) facility to produce long-life liquid milk and cream suitable for export to emerging markets such as China, Europe and the Middle East. The new facility in Monaghan is expected to be operational by early 2014 and will employ up to 40 people. It will manufacture a range of standard and fortified UHT milk and cream products, including export versions of Glanbia’s market dairy leading brand, Avonmore Milk.

The announcement follows increased collaboration between Irish and Chinese Government Officials. China is active in seeking sustainable sources of quality dairy produce globally, to meet its growing domestic demand for dairy.

In other corporate developments, Glanbia Global Performance Nutrition is locating its Europe Middle East and Africa (EMEA) head office in Dublin to support the international growth of its leading sports nutrition brand family. Glanbia Global Performance Nutrition is a Eur700 million global business. This development combined with a number of new positions being created in Global Ingredients and Global business services, will create an additional 50 skilled jobs to be located in new offices in Dublin.

Colin Gordon, chief executive officer of Glanbia Consumer Products, says: “This new state-of-the-art UHT facility is a key part of our strategy to develop an international business for Irish liquid milk and cream products. There is a strong business case for this investment and we have had an excellent response from potential customers, globally.”

He adds: “We look forward to commencing operations in 2014, with first exports planned in the second half of the year.”

Glanbia, which has its group headquarters in Kilkenny, currently employs about 2,000 people in Ireland at operations ranging from the Group Innovation Centre in Kilkenny, to its various milk processing facilities, agri mills and retail outlets throughout the South East. Its associate company, Glanbia Ingredients Ireland Limited (GIIL) is currently investing Eur150 million in building a new green field dairy processing facility at Belview, County Kilkenny – the firstgreenfieldprimariy dairy facility to be built in Ireland in over 40 years.

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£4 Million Project Completed at Grain D’Or

Grain D’Or – part of the Fletchers Group of Bakeries – has completed a £4 million expansion of its food manufacturing facilities to increase production capacity by 40 per cent and enhance technical standards. The London-based company, which specialises in continental sweet bakery products and speciality breads, has converted three industrial units into a new state-of-the-art bakery facility and despatch centre.

Two new food production areas will cater for the company’s specialist breads and sweet bakery product contracts, while the dispatch centre allows for greater flexibility for cold storage and distribution.

The project has also meant the creation of 40 permanent jobs with the company identifying skills from previous agency staff to create new full-time positions.

Grain D’Or general manager, Simon Sloan, says: “This project has allowed Grain D’Or to increase its capacity by almost double, continued its sector-leading technical standards and retained high levels of quality and food safety. As a company, the increased scale of food production area provides us with the ability to offer a wider range of products to our customers and become a more efficient and flexible operation within the market.”

He adds: “We can also respond easier to seasonal volume and growth, which often dictates the greater profit-yielding market growth areas for this industry to tap into.”

The development now brings Grain D’Or’s business premises for retail and food service sectors at Townsend Industrial Estate in Park Close NW10, to more than 100,000 sq ft.

Grain D’Or worked with Chalcroft Construction on the six month project, minimising disruption to existing production schedules and maximising the efficiency of the new plant.

An additional, second phase of the investment project, worth £250,000, will add 6,000 sq ft of dry goods storage office accommodation and a new food development facility, and is expected to be completed in August next year.

Grain D’Or’s highly-popular own-label products are supplied to major retailers and food service customers in the UK, as well as the Republic of Ireland, Scandinavia and mainland Europe. Grain D’Or’s plant is Grade A certified by the British Retail Consortium (BRC) and capable of high output, making hundreds of millions of croissants a year.

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Edrington to Invest £100 Million in New Distillery

Scottish spirits group Edrington has announced plans for an iconic new Speyside distillery and visitor centre for The Macallan, the world’s most prestigious Scotch malt whisky. The company will work with the world-renowned architects Rogers Stirk Harbour+ Partners to build the new distillery and visitor centre.

Edrington plans to invest over £100 million in The Macallan estate to sustain the craftsmanship, attention to detail, and innovation that have become the hallmarks of the brand. The Macallan is recognised around the world as the ultimate marque of excellence and innovation , and the new facility will embody these characteristics in a design that complements the natural beauty of the area and The Macallan Estate.

Creating a site of major architectural significance in the heart of Speyside will consolidate The Macallan’s position as one of the world’s leading luxury spirits. Over time the distillery is expected to deliver additional capacity to meet the growing demand from existing and new international markets.

Ian Curle, chief executive of Edrington, says: “This is a confident investment in the future of The Macallan and its home on Speyside. Our plan for the estate includes a contemporary distillery that embodies the international style of The Macallan and builds on the brand’s tradition of quality and craftsmanship. As this long-term investment develops it will bring significant employment and economic benefit to the local community.”

Ken Grier, Edrington’s director of malts, says: “As a leading luxury single malt, it was imperative that we selected an architect that understood and respected the importance of the history of The Macallan but had the experience and skills to create a building that is inspirational in its interpretation of contemporary luxury. In selecting RSHP, we have chosen a partner that shares our values and pushes the boundaries of style and quality.

“Easter Elchies House plays an integral role in the history and future of The Macallan. The proposal from RSHP will retain the integrity and importance of Easter Elchies House and the estate in the future. We are confident that this will give international visitors an outstanding impression of both The Macallan andScotlandand will build on the brand’s position as the definitive luxury spirit.”

Subject to receiving planning consent, work on the project will begin in autumn 2014 and is due to be completed in spring 2017.

Edrington owns some of the leading Scotch whisky and rum brands in the world, including The Macallan, Brugal, The Famous Grouse, Cutty Sark andHighland Park. In addition to its core brands, Edrington acquired Snow Leopard vodka in 2013.

Edrington directly controls its route to market in sixteen countries, and operates the remainder through joint venture and third party agreements. Over the past five years the company has increased the international nature of its business through the acquisition of the Brugal and Cutty Sark brands and sales and distribution companies in key markets.

Edrington is headquartered in Scotland and employs more than 2,200 people worldwide, with over 60% employed overseas.

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Arla Foods Starts Up World’s Largest Fresh Milk Dairy

The first milk for its retail customers is now rolling off the filling lines at Arla Foods UK’s new Aylesbury dairy in Buckinghamshire. Arla has invested over £500 million in the UK since 2007 and commenced building the Aylesbury site in February 2012.

The £150 million state-of-the-art dairy is set to be the world’s largest fresh milk facility with the most technologically advanced and efficient processing, and an ambition to be zero carbon when it reaches full capacity.

The new dairy will have a capacity to process one billion litres of fresh milk, sourced from the co-operative’s British dairy farmers.

Peter Lauritzen, chief executive of Arla Foods UK, says: “Our Aylesbury dairy is the largest single investment for the co-operative and, as market leader, Arla is setting the future standard for the dairy industry. We are now beginning to ramp-up our operations.”

Processing approximately 3.2 billion litres of milk a year and with a turnover of approximatey £2 billion Arla is the UK’s largest dairy company.

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