With a strong focus on automation, Chobani called on Metromotion Controls, a leading systems integrator specialising in control and automation systems, to facilitate the design, management and implementation of the new $30 million facility.
Chobani yogurt is made in this new state of the art manufacturing facility in Dandenong South, using fresh Australian milk sourced from local farmers. The yogurt is made using a centuries-old straining technique to remove excess liquid. The result is a naturally thick and creamy yogurt that has two times more protein per serving than regular yogurt.
Chobani’s commitment to the local Australian market to provide high-quality, fresh yogurt relies on the maintaining a smoothly operating manufacturing plant.
To help increase uptime, reduce overall costs and optimise inventory levels, Chobani called on the expertise of Rockwell Automation and their Authorised Distributor, NHP Electrical Engineering Products (NHP).
Chobani’s New State of the Art Manufacturing Plant
The purpose built manufacturing plant is fully automated, utilising the latest control technologies from Rockwell Automation. Metromotion Controls has enjoyed a longstanding relationship with Rockwell Automation and with extensive knowledge of their offering, was confident that their products and services were the most appropriate choice for Chobani’s plant.
“We provided ‘on the ground’ automation and resources to facilitate the site power upgrade, building services and process power distribution, integration of factory wide automation including process, packaging and site services and final commissioning,” said Andrew Sprigg, control systems engineer at Metromotion Controls.
The new manufacturing plant meets all of Chobani’s manufacturing requirements and is operating well.
According to Merome Dean, services solutions architect at Rockwell Automation, “It was important to meet project deadlines and have the plant up and running but good local support from Metromotion helped achieve this with project timelines being met.”
Assuring Yogurt Production Keeps Flowing
With global supply agreements in place, Chobani’s Australian manufacturing plant needs to maintain production rates to meet these requirements both within Australia and around the world. Any unplanned downtime can have catastrophic consequences on delivery of product, resulting in significant penalties.
To help keep yogurt production flowing, Rockwell Automation together with NHP, conducted an Installed Base Evaluation™ (IBE) to assess Chobani’s service requirements. The IBE was used to identify any risks involved at the site to minimise downtime. These findings were then used to baseline a Strategic Maintenance Program to help optimise assets and maintain operating efficiency within maintenance budgets.
The IBE at Chobani showed that there was a shortage of spare parts onsite so if a failure was to occur at the plant, there was a high risk that the associated downtime would impact yogurt production.