Mon - Fr
/
7:30AM - 5:00PM
Project Duration
January 2023 – September 2024 (21 months)
Team
18 employees led by National Operations Mngr: Tony Graham
Estimated Cost
$1.8 million
The Fonterra Te Rapa Cream Cheese Plant underwent a major expansion to meet rising global demand for frozen whole milk concentrate. The upgrade aimed to increase total production capacity and introduce greater product flexibility.
Nemesys was contracted by Tetra Pak to provide automation resources and deliver a fully integrated control system, enabling seamless operation across the plant’s new Product Chiller Systems, FOSS, and Filler lines.
Assessed process performance and integration needs for multiple product streams.
Created functional design specifications and Level 2 Grafcet FDs in collaboration with Tetra Pak engineers.
Developed PLC and HMI logic to control new chilling, filling, and monitoring systems.
Connected and tested automation layers for reliable data flow and real-time control across subsystems.
Performed on-site testing, calibration, and process tuning for maximum plant efficiency.
Delivered system documentation, staff training, and post-launch technical support.
Fonterra needed to increase output capacity while maintaining product quality and operational efficiency. The existing system lacked flexibility for new product lines and required enhanced process control to meet precision manufacturing demands.
The upgraded system allows Fonterra to efficiently diversify production, improve ingredient control, and achieve greater consistency across product batches—all while boosting total capacity by 3,500 tonnes per year.
The expansion ensures Fonterra Te Rapa remains a key player in New Zealand’s dairy export market. Through automation and smart control integration, the plant now operates with increased speed, accuracy, and reliability; supporting sustainable growth and global competitiveness.
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