Eco-friendly dairy implements SIG Combibloc filling machines

Based in Port Elizabeth, South Africa, Coega Dairy reportedly has the smallest CO₂ footprint of any dairy in the southern hemisphere. Thirteen local farmers joined forces in 2010 to create an eco-friendly, energy-efficient dairy which supports local dairy production while fostering a sustainable management system and protection the dairy region.

Due to its positioning as an environmentally friendly and energy-efficient dairy, Coega Dairy focuses not only on the dairy products and production processes, but also on its packaging. The company uses SIG Combibloc carton packs which carry the Forest Stewardship Council label.

Being made predominantly from cardboard manufactured from wood - a renewable resource - carton packs reduce consumption of fossil resources such as crude oil. Since trees absorb CO₂ from the atmosphere while growing, sustainably managed forests also help protect the climate.

When expanding its production facilities, Coega Dairy decided to use filling machine technology from SIG Combibloc. Since mid-2013, two CFA 312 filling machines have been in operation, packaging dairy products in combibloc Slimline aseptic carton packs.

The SIG Combibloc CFA 312 filling machine.

Dr Victor Korsten, the recently appointed CEO of Coega Dairy, says the filling machines are an important tool that enables his company to continue its path to success.

“The ability to fill different volumes as well as different products on a single filling machine makes us very flexible in our production. That will have a positive impact on our business going forward,” Dr Korsten said.

“Coega Dairy had SIG Combibloc’s full support from day one, which ensured a smooth and quick installation of the filling machines, and a smooth and quick start to production. That’s a good basis for a stable, long-term partnership.”

Alongside the technical support, training provided onsite at Coega’s plant and at SIG Combibloc’s training centres ensures that production runs smoothly.

Coega Dairy also uses SIG Combibloc’s Efficiency Control System (ECS). ECS is a software solution that automatically provides real-time monitoring, recording and analysis of all relevant production data. Information on the overall efficiency of all lines connected to the system, and on the productivity of individual equipment components, is displayed clearly and concisely. In this way, the ECS helps operators identify potential areas for increasing productivity, thus contributing to ongoing improvement of the production process and system efficiency. In addition, any weak points can be identified and selectively optimised.

“As a dairy industry business, we’re under a lot of competitive pressure; the ECS helps us enormously in increasing productivity and efficiency,” said Korsten. “The filling machines’ very low wastage rates are also a strong feature. That’s right in line with our own corporate philosophy.”

Coega Dairy’s Coastal View range.

“We’re very proud of the partnership with Coega Dairy. It’s an outstanding example of the positive growth within the entire region,” said Steve Stewart, Marketing Manager Sub-Sahara/South Africa for SIG Combibloc.

“Since 2001, we’ve seen growth rates of up to 35% per year in the Middle East and Africa region. Some of the reasons for this growth are that more and more food and beverage manufacturers are discovering the aseptic carton packs for their products, and they’re looking for innovative packaging formats and system solutions that are as flexible and efficient as possible. In this respect, our portfolio puts us in a very favourable position. Alongside our system of packaging materials and filling machines, our offer includes technical support and a variety of added-value services.”

Coega Dairy benefits from this as well. The company currently has a UHT full-cream milk, a low-fat and a fat-free UHT milk on the market in the combiblocSlimline 1000 mL carton pack with combiSwift screw cap. Coega Dairy also fills various UHT milk brands for one of the largest supermarket groups in South Africa, and various types of UHT milk under the brand name Coastal View. The company also offers a full-cream milk in the 500 mL volume with combiSwift under this brand name