Gemak, a leading provider of hygienic processing equipment, has announced the successful completion of “Project Dragon,” a state-of-the-art whey, milk, and cream processing facility for South Caernarfon Creameries (SCC) in North Wales. The completion of this project marks a significant milestone in the UK dairy industry, setting new standards for efficiency and environmental stewardship.
The project, which began in 2020, was part of SCC’s £15 million expansion plan to increase their cheese production capacity from 15,000 tons to 23,000 tons annually. With the support of a £5 million grant from the Welsh Government’s Food Business Investment Scheme, SCC aimed to enhance their competitiveness in the global market.
According to Alan Wyn-Jones, Managing Director of SCC, Gemak was chosen for the project due to their ability to integrate into existing processes and systems, lead times, quality, and competitiveness. Gemak, established in 1986, specializes in designing and manufacturing hygienic processing equipment for the dairy, beverage, food, plant-based, and chemical sectors.
Kursat Uysal, of Gemak UK, expressed the company’s excitement for the partnership, stating, “We were proud and excited to be chosen by SCC as their technology partner for this project and even more proud to have successfully completed and achieved KPIs. This milestone marks an important step for Gemak in entering the UK whey processing market.”
Gemak played a pivotal role in the project, designing and manufacturing a new milk and cream processing plant, storage silos, and a CIP unit for SCC’s existing cheese plant. The facility has a processing capacity of 600 tonnes per day of milk and whey concentrate, making it one of the most advanced dairy processing plants in the UK. This cutting-edge technology not only ensures high-quality products but also improves efficiency, reduces energy consumption, carbon footprint, and optimizes resource utilization.
Andrew Lyons from Engineer IQ, who led the process project management, stated, “The plant was designed to deliver optimal operational efficiency and sustainable solutions with stringent KPIs on waste levels, utility consumption, and operating costs.”
The completion of Project Dragon has exceeded expectations, achieving above-average sustainability milestones. The facility was initially designed to have a net-zero water consumption onsite; however, it exceeded expectations by generating over 100,000 litres of clean water daily, surpassing what is recovered and reused onsite. Additionally, the facility can process whey at a rate of 30 tons per hour and produce whey concentrate with an unprecedented 30% total solids, a first in the UK.
The facility’s performance has successfully met all set KPIs, including continuous run time, yield recovery per litre of whey and milk, process accuracy, and waste reduction. Alan Wyn-Jones expressed his satisfaction upon the completion of the project, stating, “Completing this project has been both a challenging and rewarding experience. Gemak’s team demonstrated dedication and expertise, making the collaboration productive. Their hard work played a key role in achieving our goals. I appreciate their commitment and look forward to future collaborations.”
The success of the project is a result of the collaborative efforts of SCC, Gemak, and their partners. Gemak worked closely with industry leaders Alfa Laval, Schneider Electric, Tetra Pak, Grundfos, and Ematics to deliver a world-class facility. Gemak also extends their gratitude to Andrew Lyons and Richard Pettifor, who played crucial roles in process design, problem-solving, and execution.
Kursat Uysal also reflected on the project’s successful completion and commissioning, saying, “We are delighted to have completed this monumental project despite the challenges along the way. Establishing one of the UK’s most advanced whey processing facilities, capable of producing whey concentrate with 30% total solids, is a milestone for the UK dairy industry and a source of immense pride for us. I would like to extend my heartfelt thanks to our valued client SCC, the dedicated Gemak team, and all our solution partners for their perseverance and commitment. By exceeding our KPIs, this project has greatly contributed to sustainability and efficiency, and we believe it will pave the way for many more important projects. We eagerly look forward to collaborating on future projects with SCC and achieving new milestones together.”
The completion of Project Dragon highlights Gemak’s leadership in providing sustainable and efficient dairy processing solutions. By breaking new ground in technology and environmental performance, the facility not only enhances SCC’s operational capabilities but also sets an example for the global dairy industry.
To showcase this achievement visually, Gemak invites you to watch their project video and witness the scale of Project Dragon come to life at https://vimeo.com/1073614693.
For press inquiries, please contact Selim Deveci at selim@gemak.co.uk or +44 7951051250.
Derick is an experienced reporter having held multiple senior roles for large publishers across Europe. Specialist subjects include small business and financial emerging markets.