Hi-tech plant meets highest standards

Hi-tech plant meets highest standards
Located in the rural community of Pokeno, northern Waikato, Yashili New Zealand’s plant is one of the first dedicated infant formula plants to be built in New Zealand.

Designed to the highest hygienic standards and operated with excellent food safety and environmental controls, Yashili’s New Zealand plant is dedicated to the production of nutritional powders for those most vulnerable -infants.
Located in the rural community of Pokeno, northern Waikato, Yashili New Zealand’s plant is one of the first dedicated infant formula plants to be built in New Zealand.
Yashili has a spray dryer where semi-finished product is manufactured and bagged, as well as a blending and canning line that utilises the semi-finished product as its base powder to produce finished infant formula.Once canned the infant formula is fully quality released before shipped, ready to be supplied to consumers.
Remy Charbonnel, Yashili New Zealand Operations Director explains that hygienic design, environmental and food safety standards are the major differences between infant formula and commodity powder production.
“The processing equipment must be easy to clean and the plant is designed to control and inhibit microbiological contamination using zoning to control the flow of people and goods.
“If you’re manufacturing commodity products you will have two or three hygienic zones at maximum, whereas in an infant formula product like ours there are four.”
All zones from low-care, like warehouses, to high-care zones, like the filling and canning rooms, have increasing levels and controls of hygiene that are separated by changing rooms for the operators and sluices for the goods.
“Each zone has an increased level of hygiene standard in terms of air purity, humidity, pressure, airflow and temperature, as well as the hygienic design of the rooms and protective clothing for the operators.
“The filling room is in the high-care zone as it is closest to the finished product. It is the most hygienic room, close to ‘white rooms’ in the pharmaceutical industry.”
“Stringent control of the air purity and micro-biological verification in the production areas is another key difference between a commodity manufacture and the production of infant formula.
“We’re doing 500 swabs in our plant per week to make sure there is no microbiological presence.“The third difference is the extent of quality and food safety controls.

Hi-tech plant meets highest standards
All zones from low-care, like warehouses, to high-care zones, like the filling and canning rooms, have increasing levels and controls of hygiene.

In an infant formula plant there are more controls at every process step. “We make sure at every step in our process we control the different powder properties and food safety hazards to ensure the product achieves the final specification.
“In the canning line, for example, there are about 50 different controls in the process, with many of the controls carried out automatically and others carried out manually.”
While the dryer has capacity to produce 60,000 tons of semi-finished goods per year, the high-speed canning line can produce 25,000 tons of finished goods per year “A certain quantity of the semi finished powder is processed into finished goods here and exported to China and Australia.
A large quantity of semi-finished powder is exported to China, Australia, Thailand and Malaysia for processing, and we will soon be exporting to Indonesia.” Last year Yashili New Zealand expanded its capability to produce sheep and goat products as well as a range of organic products.
“We’re very proud of those developments. “We have many ideas for the future and have been working on several product developments,” says Remy. “Some will eventuate in the new few months and some over the next few years.
“The plant has been designed so that we can add another dryer and canning line in the next three years or so.”
This article was brought to you in association with the following businesses…

Related Posts