Gemak supplied the whole production line incl. the fermentation tanks
Technology/IT ¦ IDM
The Collective is using a new Filltech machine for filling the ‘Plant’ range
demic, thanks to their team and Meadow
Foods working tirelessly and in harmony.
This was made possible following a
new 150,000 sq.ft. installation and assembly
factory Gemak acquired at the end of
2019 on top their existing 200,000 sq.ft.
manufacturing plant. Meadow Foods floor
plan and Gemak process equipment and
pipework installation was drawn in 3D and
fully erected and installed within Gemak assembly
plant, a first in the industry before it
was dismantled and shipped. This allowed
installation time of the plant to be reduced
by a full 8 weeks.
Gemak had the advantage of being a manufacturer
that can do a full factory installation
including electrical, ring mains, supports
and utilities off site at their plant to
minimise time on customer site and installation.
Paul Jackson, Strategic Projects Director
of Meadow foods: “We are excited to manufacture
a range of new plant-based products
that extend the strength and depth of
our product portfolio. Gemak has been a
crucial part of the project allowing us to
finish the project on time and on budget
by coming up with solutions to eliminate
the disruption caused to all by the pandemic
and lockdowns. We are very happy
with the whole experience with Gemak and
would happily work on future projects with
them.”
Ciaran Adam, Product Manager, The
Collective stated “After 2 years of tinkering,
building and designing we are very
proud to finally reveal the first plant based
Greek style "yogurt" in the UK made from
a blend of oats, coconut and rice in a fully
segregated facilty. Grown from a love of
dairy and made from plants. The products
come in a PET tub made from 100% recycled
plastic and are available nationwide
at Waitrose, Tesco, Sainsbury’s and Asda.
We have been in contact with Gemak for
nearly 2 years and having seen their high
quality work on other plants and because
of their experience with yogurt processing,
they were our preferred supplier. The
team at Gemak have worked closely with
us throughout the project and have been a
great asset in delivering the project on time
during unprecedented times.”
The plant based system includes a dry and
wet automatic multi recipe blend, process
and preparation unit, pasteurisation plant,
storage and fermentation unit, an IBC filling
station a Filltech double indexing, linear,
layered yogurt pot filling line capable
of filling 2 different diameter of pots with
auto change over. The raw and pasteurised
CIP sets were also supplied as part of the
turnkey solution.
The plant will be capable of producing
plant-based yogurt, drinks, cream, sour
cream, soft cheese, milk, custard and variety
of other alternative products and ingredients.
Kursat Uysal, Gemak UK and Filltech stated
“This is the first project where due to disruption
caused by the pandemic and lock
downs we had to change and adapt our approach
to installation by utilising our new
assembly plant to do a full factory installation
including full pipe works with ring mains,
electrical installation not just for each skid
unit but as a whole process plant within
our factory floor prior to numbering, dismantling
and re assembling on customer's
site. We would like to thank Meadow
Foods and The Collective for their fast,
flexible approach and their trust in Gemak
to deliver the whole process and packaging
plant.”
July/August 2021 ¦ international-dairy.com · 23
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