Fonterra Te Rapa: Expanding Cream Cheese Capacity

Fonterra Te Rapa: Expanding Cream Cheese Capacity

To meet growing demand for frozen whole milk concentrate, Fonterra’s Te Rapa Cream Cheese Plant underwent a major expansion. Nemesys was engaged to provide expert automation resources through Tetra Pak, ensuring the upgrade was seamless, efficient, and future-ready.

Enhancing Production with Automation

Nemesys developed Level 2 Grafcet FDs, along with PLC and HMI systems fully integrated with the new Tetra Pak Product Chiller Systems, FOSS, and Filler systems. These upgrades increased the plant’s production capacity from 30,000 tonnes to 33,500 tonnes per year, while enabling the production of five-kilogram blocks alongside the standard 20kg blocks.

Key improvements included:

• Multi-Product Capability: The plant can process Frozen Wholemilk Concentrate alongside Mascarpone and other products on the same line.
• Inline Standardising: Fat, protein, and total solids are now monitored and controlled in real time during production.
• Upgraded Conveyor System: Improved throughput, efficiency, and reliability.
• New Integrated Filler: Streamlined packaging with minimal downtime.

Technology Driving Efficiency

The project utilised industry-leading automation technology, including:

• Control Logix Process PLCs
• SICK Flexisoft Safety PLC
• Factory Talk View SE HMI
• ABB ACS Drives
• Flex IO/Point IO Racks (500 IO count)

The Nemesys Difference

By integrating advanced automation systems, Nemesys enabled Fonterra Te Rapa to expand capacity, improve efficiency, and introduce new product lines without compromising quality. Our tailored approach ensures manufacturing operations are reliable, consistent, and scalable, giving operators and managers complete visibility and control.

Delivering Results

The expansion demonstrates how precision automation can directly increase plant output, enhance product flexibility, and maintain high standards of quality and safety. Nemesys continues to help New Zealand manufacturers achieve measurable performance improvements through expert automation solutions.

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