IDM | Site report
Construction phase
GEA was responsible for the construction
of the milk powder plant (excluding
boiler, water, wastewater treatment &
chilled water plants) cooperating with
a local project engineering office. They
have developed an integrated design
and construction process based on 3D
models and engineering know-how to
integrate the process plant and the
building as it is erected. Part of the
supply included four additional tanker
unloading bays capable of feeding raw
milk silos prior to the milk treatment
and standardisation process. Other core
components of the supply included
evaporation, CIP systems and powder
handling and storage systems Lichfield
features three fully automated packing
lines each capable of inert gas packing
wholemilk powder at up to 12 tonnes
per hour. An automated palletizing system
with three robots and a wrapper/
labeller completed the plant. GEA was
also responsible for full plant automation
and control including the ventilation
systems.
GEA had up to 350 people working onsite
during construction and installation
stages, many more were involved in prefabrication
and manufacturing.
Volume of production
Technical details:
• Overall milk throughput is approx.
4,700 m³/day processed through four
evaporators’.
• The dryer is fed with a concentrate,
producing powder output of 30,000
kg per hour
• Two skid mounted RO Polishers capable
of polishing up to 250,000 litres
per hour of evaporator condensate/
recovered water were included in the
36 · 8 2017 | international-dairy.com
The Lichfield team in front of the mega-dryer during the first production run (photo: Fonterra)
project. The plant generates more
potable water per day than it consumes,
with a daily excess of over 1
ML per day.
• Steam and electrical power consumption
are at industry leading low levels,
and fell well within the guarantees
agreed at the project outset.
• To achieve overall output requirements,
GEA supplied three RBF1200Li
(limited intervention) filling lines each
with a peak output of 12MT per hour
fill powder into 25 kg kraft paper bags
with a gas barrier liner. The GEA Avapac
RBF’s feature fully automated
empty bag handling and filling capability
meaning that all three lines can be
operated by a single operator.
Fonterra’s comments
Fonterra’s Chief Operating Officer Robert
Spurway commented, "Premium milk
powder is a valuable product for Fonterra
in its own right but people often un-
derestimate the strategic importance of
powder production to the Co-operative’s
overall asset mix. The capacity these assets
give us takes the pressure off during
the peak of the season, meaning, we
have more freedom to prioritise milk into
higher returning products."
"Our goal is to strike a balance in our
assets that enables us to switch between
products quickly to meet demand
changes in global markets, push
the pace on production when milk volumes
dictate, and ultimately deliver the
best product mix to generate returns,"
said Mr Spurway.
South Waikato Operations Manager
Sam Mikaere added, "The successful
commissioning of this project is the result
of an exceptional breadth of experience
and knowledge. We sought expertise
locally, nationally and globally from
more than 200 companies and their
dedication has seen the project come in
on time and under budget."
Standardization and pasteurization department
at the Lichfield plant (photo: GEA)
Limited intervention filling lines operating
in the Lichfield plant (photo: GEA)
GEA has developed an integrated design
process based on 3D models (photo: GEA)