Client Overview: EPIIM Tootmine AS
In 2021, EPIIM partnered with Royal A-Ware and Interfood Group to establish a €154M greenfield dairy plant in Paide, Estonia. Assisted by the European Investment bank, the facility integrates advanced processing, automation, and digitalisation technologies, setting a benchmark for sustainability and competitiveness in the global dairy market. The plant began operations in September 2023, producing Cheddar, Gouda cheese, and Whey Powder using cutting-edge processes and renewable energy sources. By March 2024, EPIIM had earned recognition as “Responsible Factory of the Year” at the Smart Industry 2024 awards in Estonia, affirming their commitment to climate neutrality and operational excellence.
Challenge: Innovating Cheese Block Handling
EPIIM sought to revolutionise traditional cheese block production by eliminating cardboard usage in case packing for their 20kg blocks. However, this posed significant challenges:
Warm, soft blocks required gentle handling to prevent deformation and damage during cooling and storage.
Shape integrity and block firmness had to be achieved to ensure stackability and quality before Warehousing
Flexibility was essential to meet export market demands, which occasionally required cardboard-cased blocks.
Solution: Turnkey End-of-Line Automation by Power Food Technology (PFT)
With over 30 years of expertise in 20kg cheese block handling, PFT was invited to provide a comprehensive solution. This involved:
- Custom Cheese Crate System:
- A fully automated system for loading and unloading cheese blocks into reusable PFT cheese crates.
- Capacity to handle up to 8 blocks per minute, ensuring gentle and precise block placement.
- The crate handling system incorporates the seamless transfer of unloaded crates back to the loader removing the need for manual handling.
- Automatic Rapid Cooling Technology:
- Rapid cooling reduced block temperature to 12°C, achieving consistent shape and firmness.
- Achieved enhanced product quality with reliable flavour profiles and minimised deformation during storage.
- Automated Palletising Integration:
- After cooling, blocks were gently conveyed to the palletising system, ensuring damage-free transfer and optimal pallet build.
- Export-Ready Flexibility:
- For markets requiring cardboard-cased blocks, an automated diversion to the PFT Wrap Around Case Packer was implemented via a simple code change.
- Blocks can be rerouted, cased, relabeled, and returned into the line for palletising.
Implementation Highlights
- Customised Controls & Automation:
- PFT adapted its systems to EPIIM’s plant standards, switching from its default Allen Bradley PLCs to Siemens automation for seamless integration.
- Interfaces were customised to align with upstream and downstream equipment.
- No manual handling.
- End-to-End Installation:
- PFT managed the entire installation, commissioning, and testing process, reducing project management burdens for EPIIM.
- Turnaround & Results:
- Contract awarded: Q3 2022
- Installation: Q2 2023
- Handover: Early 2024
Impact & Benefits
- Sustainability: Eliminated cardboard usage for the majority of production, supporting EPIIM’s climate neutrality goals.
- Efficiency: Automated processes reduced manual handling, improving safety and throughput.
- Product Quality: Rapid cooling ensured consistent shape and flavour, enhancing product reliability.
- Flexibility: Export readiness with a simple program switch for cardboard-cased blocks.
- Recognition: Contributed to EPIIM’s win as “Responsible Factory of the Year.”
Client Testimonial
“The collaboration with PFT was seamless and impactful. Their innovative end-of-line solution has transformed our cheese block handling process, enabling us to deliver high-quality products sustainably and efficiently to global markets.”
— EPIIM Tootmine AS
