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Fonterra's Te Rapa Cream Cheese Plant expanded its operations to meet rising demand for frozen whole milk concentrate. Tetra Pak contracted Nemesys to supply the automation resources behind the upgrade, developing Level 2 Grafcet functional designs and building the PLC and HMI systems that integrate with Tetra Pak's new Product Chiller systems, FOSS analysers, and filler equipment.
The result lifts annual plant capacity from 30,000 tonnes to 33,500 tonnes and extends the plant's range to manufacture five-kilogram blocks alongside its existing 20-kilogram production.
The new production stream gives the Te Rapa plant:
Total I/O count: 500
By integrating Tetra Pak's chiller, FOSS, and filler systems under a unified control architecture, Nemesys delivered a more flexible, higher-capacity production stream. Te Rapa can now produce a broader product mix at greater volume, meeting frozen whole milk concentrate demand while holding the quality control standards Fonterra requires.
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