Coega Dairy UHT Processing Plant, Eastern Cape

Coega Dairy opened a new ultra-high temperature (UHT) milk processing facility in Coega-harbour, South Africa, in September 2011. The processing capacity of the plant is 150,000l of milk each day.

Coega Dairy opened a new butter factory within the UHT processing plant with an estimated investment of R50m ($7.3m) in April 2012. Coega Dairy is planning to invest a total of R175m ($25.56m) in the plant by 2015. The investment is expected to create 350 direct and 750 indirect jobs.

The shareholders of Coega Dairy include Coega Milk Producers Organisation (CMPO) and Coega Empowerment Trust (CET). CMPO holds a 61.4% stake and CET holds the remaining 38.6% stake in Coega Dairy.

CMPO consists of 13 of the biggest commercial milk farmers in South Africa. CET consists of Amadlelo Projects Trust (a black empowerment agri-business), Coega Dairy Factory Workers Empowerment Trust, and Commercial Farmers Empowerment Trust.

The Coega UHT Plant received the Big Brand Supplier of the Year Award from Shoprite in January 2013.

Efficient UHT milk processing

The UHT plant was conceived by Coega Dairy in 2010 to improve the quality of locally produced milk using environmentally-friendly methods. South African dairy farmers face tough competition from countries where milk can be produced in more cost-efficient ways.

The farmers receive subsidies in these countries while South African farmers face the challenges of high input costs and low product prices.

To address these challenges, Coega Dairy decided to invest in a technology which will generate significant cost savings while being environmentally-friendly. The Coega plant is more efficient than traditional UHT milk processing plants and has the smallest carbon footprint in the southern hemisphere.

Location of the Coega UHT plant

Coega Dairy decided to build the plant in Coega due to the infrastructure available in the Coega Industrial Development Zone (IDZ) near Port Elizabeth. Coega IDZ has a well connected road network and a reliable source of power. It is also ideally located near Coega Dairy’s milk supply region.

Processing and packaging technology at the UHT facility

The UHT plant is equipped with state-of-the-art processing and packaging technologies. The milk delivered by the suppliers is received at the milk procurement area in the plant.

The processing plant includes UHT equipment and a number of other solutions supplied by Tetra Pak. It uses Tetra Pak’s Tetra Lactenso Aseptic with OneStep technology to produce high-quality products. The plant uses 50% less energy, water and chemicals and also emits 40% less carbon compared with other UHT facilities.

The plant also features an R&D laboratory equipped with product evaluation facilities to ensure the quality of the milk produced. A warehouse space for product handling and distribution to retailers is also part of the plant.

Tetra Pak equipment at Coega Dairy’s UHT milk plant

The Tetra Pak’s OneStep technology uses a single step in which raw milk is preheated, clarified, separated, standardised and homogenised. The next step includes UHT treatment and regenerative cooling. Processed milk is then sent to the aseptic buffer tanks. The whole process is highly efficient as it reduces the processing time and enables automated and continuous operations.

The technology uses only 300ml of water for every litre of milk compared with conventional UHT technology, which uses three litres of water. The technology also requires less cleaning.

Milk processing plants usually require daily cleaning using large quantities of water and chemicals. Some of these chemicals are expensive and are released along with the plant’s effluents, which is harmful to the environment.

With OneStep technology, the cleaning interval of the processing plant is 60 hours. In addition, less water and fewer chemicals are needed for cleaning. As a result, the plant produces 50% less effluent, of which 65% can be recycled. This also reduces production downtime and increases the efficiency of the plant.

The OneStep technology includes a Floating Protection System to improve the food safety of dairy products, and the Tetra Spiraflo, a tubular heat exchanger with thermal-stress absorbing design which enables high-energy recovery to reduce energy consumption.

Tetra Centri AirTight Eco, Tetra Alfast, Tetra Alex and Tetra FlexDos are also key components of the Onestep technology.

New products and brands from the South African milk processing plant

The Coega plant produces value-added and environmentally-friendly milk products including UHT milk, custards and butter. The milk is produced under the Coastal View brand in three variants – full cream, 2% low fat and fat free.

The Coastal View brand was first launched in 2012 at Eastern Cape. The Coega Company is planning to launch the Coastal View brand in the international market by 2013.

Coastal View milk products are available in one litre slim packs and six-pack carry packs. The slim packs feature an easy-to-open and pour twist-top cap.

Coega Dairy is planning to add more value-added products to this range in future. These products will be targeted for exportation.

Sustainability features and OneStep technology at Coega Dairy’s facility

The OneStep technology of the plant reduces the amount of effluents produced by the plant. The packaging of the products is also through sustainable methods. The products are packaged in recyclable paper cartons. Cartons can be pulped and paper fibres can be recovered to make new products. The remaining aluminium and plastic can be used for power generation.

The milk supplied to the facility and the finished products from the facility are not transported over long distances. This reduces the logistics and transport carbon emissions of the facility.

Future plans

Coega Dairy is planning to construct a new cheese plant near the UHT processing plant in Eastern Cape in a joint venture partnership with Famous Brands, a franchise restaurant group based in South Africa.

Famous Brands-Coega Dairy will invest R55m for the cheese manufacturing facility. The investment includes construction and importing of the latest technology equipment from Italy.

Famous Brands will hold a 51% stake in the project while Coega Dairy will own the remaining 49% stake.