Carlisle Process Systems

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Carlisle Process Systems
The Challenges of Building a Modern Cheese and
Whey Plant The Southwest Cheese ProjectTim
HighPresident, CPS, Inc.

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US Cheese Production Consumption Trends

• From 1970 to 2004
• The number of cheese factories has decreased from
  963 to 401
• Average production per cheese plant increased
  tenfold from 2.29 million pounds to 22.14 million
  pounds
• Milk production in the USA is moving from East to
  West, with New Mexico and the Texas panhandle
  being the most rapidly growing area
• Favorable climate
• Land availability
• A labor force providing for large scale, low cost
  milk production
• New Mexico has an average herd size of almost
  2000 cows- twice that of any other state

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US Cheese Production Consumption Trends

• Cheese Producers
• 401 cheese factories in the USA
• SWC will be 402
• Gossner Foods, Magic Valley Swiss Cheese Plant
  will be 403

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US Cheese Production Consumption Trends

• US Cheese Production 2004 Percent by Type

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US Cheese Production Consumption Trends

• Cheese Consumption

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US Cheese Production Consumption Trends

• Commercial Disappearance USA

US cheese consumption is dependant on its
popularity as a food ingredient rather than
Americas appetite for cheese itself.
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Southwest Cheese Project Joint Venture Partners

• Glanbia
• International cheese, nutritional ingredients and
  consumer foods company
• Operations in the USA, Ireland and the UK
• Largest dairy processor in Idaho, USA and is a
  global player in advanced technology dairy-based
  nutritional ingredients
• Headquartered in Kilkenny, Ireland
• Group sales in 2004 of 2.5 billion. 
• Dairy Farmers of America, Inc.
• Headquartered in Kansas City, Missouri,
• Largest dairy co-operative in the United States
  and the largest marketer of fluid milk in the
  world
• During 2004, DFA marketed 57.2 billion pounds of
  milk, constituting 34 of total US milk
  production
• Operates 27 manufacturing plants that produce a
  wide range of dairy products
• 2004 sales amounted to 8.4 billion
• Select Milk Producers Inc.
• Formed in 1994 by a group of large dairy
  producers in New Mexico
• Majority of members are located in the New
  Mexico/West Texas region which is the fastest
  growing milk producing region in the USA
• Supplies a range of Americas leading food
  manufacturers with quality fluid milk, both
  natural and concentrated, for further processing
• 2004 Select sold 3.3 billion pounds of milk with
  a value of 550 million.

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Southwest Cheese Project By the Numbers

• Sales 340 million per year
• Employ over 225 staff
• At full capacity
• Process over 2.3 billion pounds/1 billion litres
  of milk
• Produce in excess of 250 million pounds/110,000
  tonnes of cheese
• Produce 16.5 million pounds/7,500 tonnes of high
  value-added whey proteins each year
• Capacity Cheese Plant
• Manufacture 25,000 pounds/11 tonnes of 640
  blocks per hour and 19,000 pounds/8.6 tonnes of
  40 blocks per hour
• Total manufacturing capacity of 44,000 pounds/20
  tonnes per hour
• Cheese type American style cheeses - cheddar,
  Colby, jack and pepper jack
• Capacity Whey Plant
• 275,000 pounds/125,000 litres of whey per hour
• Producing the highest quality WPC 80 and WPI in
  the industry

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Southwest Cheese Project Implementation

• Selection of General Contractor Equipment
  Vendor
• Budget Preparation
• Value Engineering
• G-max
• 90 Engineering
• Release for Construction
• First Product
• Substantial Completion
• Final Completion

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Southwest Cheese Project Implementation
Southwest Cheese Board of Directors
Glanbia Foods
Southwest Cheese Project Manager
Dahlgren/Skanska Building Utilities
Infrastructure Effluent AE Bonnelli
CPS Process Packaging Filtration
Engineering Tetra Pak Millerbernd Design
Fabrication Alfa Laval Emerson Rockwell Fristam
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CPS Scope

• 70 million order value
• 250,000 CPS man hours (125 man years)
• Third party equipment 26 million

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Southwest Cheese Project - Equipment

• CPS was awarded the contract in December 2003
• CPS began delivering equipment in May 2004
  including
• Milk Receiving and Treatment
• Fifteen Scherping Horizontal Cheese Vats (70,000
  lb/31,000 L)
• Two 12ft. x 116 ft. Scherping Draining/Matting
  Machines
• Two 12ft. x 60 ft. Scherping Salting Mellowing
• Fourteen Hi-Flo Cheese Towers
• Eighty Walker Silos and CIP tanks
• Zimmer Permeate Evaporator
• Stork WPC/WPI Dryer
• Automation
• Consignment spare parts inventory program

Horizontal Cheese Vat
Cheese Curd Draining Conveyer
Shaking Bed
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Southwest Cheese Project Implementation

• Challenges
• Massive paper trail and revisions
• Web site used to manage thousands of documents
• Stainless steel price increases
• 3 million pounds used
• 50 price increase
• Location
• Shortage of skilled workers
• Weather
• Delayed building/road construction by 3 weeks

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Southwest Cheese Project Implementation

• Highlights
• Within original budget plus contingencies
• Ground break to first product in 20 months
• Pre-engineering and value engineering phases
  resulted in few price variations and substantial
  cost savings
• Over one million hours worked on site with no
  serious injury

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Southwest Cheese Project Plant Details

• Total Plant Area
• 280,000 sq ft/ 26,013 m²
• Main Areas
• Cheese Plant
• Whey Plant
• Storage
• Office, Maintenance, Corridor
• The site comprises approximately 54 acres of new
  grading and construction

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Southwest Cheese Project Schedule
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Southwest Cheese Project
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Southwest Cheese Project
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Southwest Cheese Project
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Carlisle Process Systems
Carlisle Process Systems