Complete Cheese Manufacturing Plant (36T in 24hrs) Located in Ireland

Complete Cheese Plant located in Ireland available immediately. 

Current cheese production setup: Cheese blocks are in a 60 kg format to match the process floor moulds, x30 blocks of cheese per vat, x20 vats per run x1.8/vats equals 36.0 tonnes of cheese in 24 hrs.

Milk silos external:

Milk silo 1 - 136000 ltr - Installed 2006

Milk silo 2 - 136000 ltr - Installed 2006

Milk silo 3 - 136000 ltr - Installed 2006

Milk silo 4 - 160000 ltr - Installed 2007

Milk treatment room:

Milk separator (originally the milk clarifier) - 22000 ltr

Milk Bactofuge - 22000 ltr

Plate plant including pasteurization section - 22000 ltr

Regens 1+2 from 4C to 30C - 22000 ltr

Tetra alfast system (online milk STD) - 22000ltr

Whey room:

Whey Clarifier - 22000 ltr

Whey cream separator - 22000 ltr

Whey cooling plant - 22000 ltr

Whey cream storage and cooler - 5000 ltr

x2 Robots:

RWBT 1 - 30000

RWBT 2 - 30000

x2 Final whey silos:

Whey silo 1 272000 ltr

Whey silo 2 272000 ltr

Vats:

Vats 1 APV 22,000 ltr - Installed Prior 2006

Vats 2 APV 20,000 ltr - Installed Prior 2006

Vats 3 APV 20,000 ltr - Installed Prior 2006

Vats 4 APV 22,000 ltr - 2007

SPX rennet dosing system

x2 curd pumps:

Old curd pump 22000/Hr - N/A

New curd pump 22000/Hr - 2007

x2 pre-presses and block format:

Press-vatic 1 1.8T/hr - 2007

Press-vatic 2 1.8T/hr - 2007

x5 main presses:

Press 1 - 0.45T/hr - 2007

Press 2 - 0.45T/hr - 2007

Press 3 - 0.45T/hr - 2007

Press 4 - 0.45T/hr - 2007

Press 5 - 0.45T/hr - 2007

x4 holding tables:

Holding table 1 - 2007

Holding table 2 - 2007

Holding table 3 - 2007

Holding table 4 - 2007

Demoulding unit and washer: 2007

MF plant (brine) x1 unit: 1146 litres/Hr - 2007

Brine:

Automated crane - Timed/programmed - 2007

Brine basin 1 (14 racks per basin) - 12.6T - 2007

Brine basin 2 - 12.6T - 2007

Brine basin 3 - 12.6T - 2007

Brine basin 4 - 12.6T - 2007

Brine basin 5 - 12.6T - 2007

Brine basin 6 - 12.6T - 2007

Brine basin 7 - 12.6T - 2007

Brine basin 8 - 12.6T - 2007

Brine basin 9 - 12.6T - 2007

113.4T brining capacity

Brine silo x1:

Brine silo - 55000 - 2007

Brine mixing silo:

x1 mixing tank and auger - 3000 - Prior 2006

Cut and pack room:

Ferrai machine (block cutting options) - 5T/Hr - 2017

Cryovac machine - 5T/Hr - 1980

Metal detector - 5T/Hr - Around 2006

DEM labeller - 5T/Hr - 2018

Bypass - 4T/Hr - Around 2010

Robots x2:

Fresh (brined cheese) - 5T/Hr - 2007

Mature(ripened)/deboxing - 5T/Hr - 2007

Whey: Liquid whey volume generated per hour or per vat is around 17,500 litres. Solids 6/7%.

Kg's of fat removed from the whole milk: Determined by the standardized fat required in the cheese, typically 700-800 litres per hour generated.

Cheese process:

Milk filling into the vat takes at a maximum one hour, it can be less depending on flow rate and % protein in the raw milk, generally we add the DVS culture 20 mins into the milk fill i.e. it has 40 minutes to pre acidify/ripen.

Then we add the rennet, cut, stirring and cooking, stirring and vat empty.

From the vat empty/pitching we then transfer the vat contents to one of the two press vatics, then pre pressing occurs, then unloading the cheese into the white 60 kg moulds, then it is transferred to main presses, once pressed it then goes on to the holding tables and finally transferred to brine.      

Total time from the start of filling a vat to empty/pitching is 2 hrs 40 mins. (note: one hour of this time I physically filling the vat with milk).         

Total time for emptying/pitching the vat and pre pressing it in a press vatic is 60-65 mins.

Total time for unloading cheese from the press vatic (pre-press) to transferring it into the brine is max 14 hrs.

Total time from start of filling milk into a vat until it is transferred to the brine is typically 18 hrs in the system.

Target production = 20 vats in 24 hrs. (realistic target but some capex is needed to hit this target consistently).

Target daily production is 20 x 1.8/ vat = 36 tonnes per day.

Target weekly production = 252 tonnes.

Target monthly (x4 weeks) = 1,008 tonnes. (Note this is 100% efficiency).