Gemak has successfully completed “Project Dragon”—a state-of-the-art whey, milk and cream processing with CIP units for South Caernarfon Creameries (SCC) in North Wales. From its inception to commissioning, this project highlights a transformative journey in the UK dairy industry, setting new benchmarks in efficiency and environmental stewardship.
South Caernarfon Creameries, Wales’ oldest and largest farmer-owned dairy co-operative, embarked on a £15 million expansion plan to increase its cheese production capacity from 15,000 tonnes to 23,000 tonnes annually. Backed by a £5 million grant from the Welsh Government’s Food Business Investment Scheme, this investment aimed to bolster SCC’s resilience and competitiveness in the global market.
Alan Wyn-Jones, Managing Director of SCC, said: “After a thorough tendering process, Gemak was chosen due to their ability to integrate into our existing processes and systems, lead times, quality and competitiveness.”
Established in 1986, Gemak specialises in the design and manufacture of world-class hygienic processing equipment and engineered solutions for the dairy, beverage, food, plant-based, and chemical sectors.
Gemak’s role in “Project Dragon” was pivotal. Besides leveraging its expertise in designing and manufacturing hygienic whey processing plant, the project also included a new milk and cream processing plant, storage silos, and a CIP unit for SCC’s existing cheese plant. The facility boasts a processing capacity of 600 tonnes per day of milk and whey concentrate, making it one of the most advanced dairy processing plants in the UK. This groundbreaking technology not only ensures exceptional product quality but also streamlines processes, reducing energy consumption, reduction in carbon footprint and optimising resource utilisation.
Kursat Uysal of Gemak UK expressed the company’s enthusiasm for the partnership: “We were proud and excited to have been chosen by SCC as its technology partner for this project and even more proud to have successfully completed and achieved KPIs. This milestone marks an important step for Gemak in entering the UK whey processing market.”
The completion of Project Dragon goes beyond conventional targets, achieving above expectation sustainability milestones. Initially designed for net-zero water consumption on-site, the facility exceeded expectations, earning a “Net Zero Plus water” distinction by generating over 100,000 litres of high-quality clean water daily beyond what is recovered and reused on-site.
Gemak also delivered a facility capable of processing whey at a rate of 30 tonnes per hour and producing whey concentrate from RO (HIRO) with an unprecedented capability of 30% total solids—a first in the UK.
Gemak’s completion of Project Dragon underscores the company’s leadership in sustainable and efficient dairy processing solutions. By breaking new ground in technology and environmental performance, the facility not only enhances SCC’s operational capabilities but also sets a precedent for the global dairy industry.
As Gemak continues to push the boundaries of innovation, this project serves as a shining example of how industry collaboration can lead to transformative achievements in sustainability and efficiency.
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