Gemak builds dairy processing project in Wales

Credit: Gemak
Gemak UK proudly announces the successful completion and commissioning of one of the most advanced dairy processing facilities in the UK. This milestone project underscores the company’s commitment to innovation, sustainability, and operational excellence. As its largest turnkey dairy plant installation in the UK, it boasts a process capacity of 600 tonnes per day of milk and whey concentrate. Located in Wales, the facility is setting a new benchmark in the dairy industry by achieving unparalleled levels of efficiency and environmental performance.
High percentage of total solids
For the first time in the UK, the plant incorporates a continuous RO (HIRO) system capable of producing whey concentrate with 30% total solids (TS). This groundbreaking technology not only ensures exceptional product quality but also streamlines processes, reducing energy consumption, reduction in carbon footprint and optimising resource utilisation.
Beyond net zero
Originally designed to meet net zero water consumption targets, the facility has surpassed expectations, earning a “Net Zero Plus water” distinction. By generating over 100,000 litres of extra high quality clean water daily beyond the water recovered and reused on site, the plant showcases its versatility and sustainability. This achievement reflects a significant leap forward in sustainable water management within the dairy sector, the company notes.
Redefining industry standards
Gemak’s commitment to delivering integrated solutions has enabled this facility to exceed its key performance indicators (KPIs) and deliver the tangible benefits of: continuous run time, performance parameters, utility unit consumption per litre of whey and milk, plus and minus percentage process accuracy and net zero water.
This project reinforces Gemak’s position as a leader in the design and manufacture of world-class hygienic processing equipment and engineered solutions for the dairy industry and beyond. By continually pushing the boundaries of what is possible, Gemak is proud to play a role in shaping a more sustainable and efficient future for food production.
“This achievement would not have been possible without the dedication, expertise, support and teamwork of our customer and the GEMAK A.Ş. team. A huge thank you to both. We also extend our gratitude to our valued solution partners— Tetra Pak Processing Equipment GmbH, Alfa Laval , Morson Projects , GRUNDFOS, Schneider Electric for their support and collaboration on this project.” announced the company.