Sycamore Process Engineering has successfully delivered a major process expansion project for Yeo Valley at its Crewkerne, UK production facility, increasing yogurt production capacity, improving operational efficiency and supporting future growth, the company says.

As part of a wider investment programme aimed at increasing production throughput and supporting the introduction of a new high-speed filling line, Yeo Valley sought to enhance its existing strained yogurt mixing capabilities while reducing manual intervention within the process.

Following a competitive tender process, Sycamore Process Engineering was selected to design, manufacture, install and commission a fully integrated solution that would expand capacity, improve process automation, and provide a scalable platform for future production requirements.

The project centred on the expansion of the site’s existing yogurt processing system, including the installation of two additional 7,000-litre mixing tanks, effectively doubling available mixing capacity. The scope also included an extension to the existing UF membrane system, a new mix-proof routing manifold, and upgrades to process pipework, valves, instrumentation and control systems.

A feature of the solution was the implementation of a fully automated in-line fruit dosing system. Replacing the previous manual fruit handling process, the new system delivers precise and consistent fruit addition directly into the production line. This provides improved product consistency while reducing labour requirements, minimising product waste, and enabling faster product changeovers between different yogurt variants.

To maximise operational flexibility, the system was designed to allow simultaneous filling and emptying of all mixing vessels. Automated control of temperature, agitation and tank levels ensures that product quality is maintained throughout the process, while advanced mix-proof valve technology enables safe and efficient product routing. Integrated Clean-in-Place (CIP) functionality further supports reliable and repeatable cleaning procedures, helping to maintain the highest standards of hygiene and food safety.

Delivered in a live production environment, the project was carefully planned and executed to minimise disruption to ongoing operations. Working in partnership with Yeo Valley’s production and engineering teams, Sycamore successfully completed the installation and commissioning works while maintaining site productivity throughout the project lifecycle.

The expansion was fully integrated into the site’s existing PLC and SCADA systems, providing operators with enhanced real-time process visibility and control. Automated sequences for filling, emptying, dosing and cleaning have streamlined operations and reduced operator intervention, contributing to improved overall plant efficiency.

The completed project has significantly increased production capacity at the Crewkerne facility while establishing a flexible foundation for future expansion. By combining increased throughput with greater automation and operational efficiency, the solution positions Yeo Valley to meet growing consumer demand while maintaining product quality standards.