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MORWELL MANUFACTURING PLANT PRESENTED BY HOWARD VELLA (MANUFACTURING MANAGER) Growing sociability and wellbeing in our world.

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Presentation on theme: "MORWELL MANUFACTURING PLANT PRESENTED BY HOWARD VELLA (MANUFACTURING MANAGER) Growing sociability and wellbeing in our world."— Presentation transcript:

1 MORWELL MANUFACTURING PLANT PRESENTED BY HOWARD VELLA (MANUFACTURING MANAGER) Growing sociability and wellbeing in our world

2 2 The story so far Our product range Some statistics Future Opportunities Agenda

3 3 Morwell Site History ConceptionAugust1996 Board approvalNovember 1996 Construction started at MorwellJanuary 1997 Production ex Murray BridgeSeptember 1997 National Foods acquire DFNovember2008 NF acquired by KIRIN HoldingsDecember 2009 Project Rainbow Announced June 2010

4 4 Aerial View New Engineering W’shop

5 Current Range of Products 5

6 Products Still Under Transition 6

7 Yoghurt Manufacture Milk High quality with low bacteriological levels Homogenisation Prevents creaming, and distributes fat Pasteurisation At 91°C for 5 minutes, improves the milk for the addition of culture, and ensures the end product’s consistency is thick and creamy Reduces the risk of whey separation Cooling To 41°C for inoculation with culture Incubation 8 to 10 hours Cooling To stop the incubation process Filling /packing Into pots of various sizes, fruit added if required Cold room Temperature brought down to 4°C before transportation to depot 7

8 8 Site Numbers Factory Size (approx.)12000 sq. m Employees162 (plus casuals) Raw Materials Storage435,000 litres Stock Keeping Units (SKU’s)>100, over 21 bases Production Lines11 Production Volume ,000 Tonne ,000 Tonne Processing capacity 91,000 Tonne (53,000T pre Rainbow) Product Range Yoghurt – stirred and set Dairy desserts (custardd & Fruiche) Sour cream

9 9 Site Capability Pre RainbowPost Rainbow Processing – annual tonnes - Yogurt44,00078,700 - Desserts7,800 - Sour1,2004,500 Total53,00091,000 Pilot Plantnil1 Filling – million cups / week - FFS13.4 (4 lines)16.8 (4 lines) - Pre Form Cup3.9 (4 lines)8.0 (5 lines) - Tubes3.2 (1 line) - Pallecon Filler.16 (1 line).29 (1 line ) Total Inbound Warehousing1,6782,435 Cooling Cells96125 Warm/Hot Room40130 Cold Room300 pallets

10 Processing Plant 10 Base o Stirred Yogurt o Natural Set Yogurt o Fromage Frais o Custard o Sour Cream Processing Plant Stats o 2 Pasteurisers o 17 Maturation Tanks o 26 PFS Tanks o Max Processing Capacity is 91 million kgs per annum

11 11 Filling Line New Arcil Filler Tecma Pak Case Packer New Ermi Filler Fruit Dosing

12 12 Automated Pallet Movement

13 13 Packaging Warehouse

14 14 Rainbow & Morwell 2025 Rainbow o Strategic intention of removing excess capacity in Dairy industry o Create centre of dairy foods Morwell o Support capacity / growth and innovation to 2014/15 o Introduction of shelf ready packaging Morwell Future – 2025 o Planning in progress to review Morwell foot print requirements; o Normal Growth o Repatriation of 3 rd party manufacture – Pouches & Le Rice o Consider emerging trends in categories and capabilities o Desserts, Pot set

15 15 Morwell Projects ProjectTimingProgress Reformulation of Light & Original Yoplait and Yoplus and introduction of sleeved 4 pack February 2012 Complete Replacement of Hassia Tube line with Arranow filling LineApril 2012 In Progress Construction of humidity and temperature controlled shelf life Incubation Room January 2012 In progress Development of Dairy Dessert product lines in square tub format and increase in Pallecon filling capacity June 2012 In progress Modification of downstream packaging equipment to facilitate shelf ready packaging formats for major grocery customers June 2012 Complete Devoted underground electricity supply via Vic Govt supportLate 2012 Approved Developing Morwell footprint strategy and business case for the next generation of growth and innovation Qtr In progress

16 16 Thank you Questions ?


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