pladot mini dairy ebrochure - · pdf fileat the core of pladot’s mini dairy program is...

Pladot Mini DairyPladot Mini DairyPladot Mini DairyMiniaturized Dairy Processing SystemMiniaturized Dairy Processing System

A comprehensive, cost effective and rapidly deployable solution for manufacturing high quality dairy products

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The Pladot Mini Dairy is a miniaturized dairy processing facility that includes all the equipment required to manufacture a very wide variety of dairy products. The facility is tailored to occupy small physical spaces, and is uniquely suited to process smaller lots of more specialized products close to their target markets.

Pladot, a metals fabrication company with more than fifty seven years of experience, has been designing, manufacturing, and installing Mini Dairies for over 15 years. The company has installed and trained employees to operate 300 Mini Dairies in Israel and overseas. Since 1999, Pladot has installed 10 Mini Dairies in the US Eastern Corridor with more units nearing completion in the Midwest.

Unlike any other equipment supplier and unlike any other food processing concept, Pladot offers the Mini Dairies as a competitively priced package of equipment, engineering, implementation and training services thereby reducing the initial investment and time required to provide ultra fresh, high quality dairy products close to target markets.

This document provides comprehensive insight on Pladot’s Mini Dairy concept. The reader will find a review of the equipment and services Pladot provides as part of the Mini Dairy package, as well as examples of the prolific processingcapabilities these miniaturized facilities provide.

We hope you will find this document useful and informative. And we hope you will find interest in Pladot’s Mini Dairy concept. Pladot’s management invites you to learn more about us, our products and capabilities and will be honored to introduce you to the Mini Dairy’s many exciting advantages and capabilities. Our business development and engineering team looks forward to answering your questions in the professional and quality-driven manner that has been our hallmark and tradition for over 50 years.

PladotPladotKibbutz Ein Harod Meuhad, 18965 Israel Phone 1.888.521.3030 Fax 011.972.4.653.1641

E mail [email protected] Web www.pladot.com

Pladot Mini DairyPladot Mini DairyMiniaturized Dairy Processing System

An IntroductionAn Introduction

As our world evolves into a global community, tastes and appetites evolve and extend beyond the confines of geography, tradition and availability. Consumers desire original culinary tastes, textures and sensations and appreciate newfound diversity in the foods they consume at home. People accessing greater amounts of information and households growing more prosperous generate increased demand for innovative specialty groceries and gourmet foods. Customers concerned about health and well being seek flavorful foods that are local, fresh, natural and conservatively processed.

The Pladot Mini Dairy (PMD) is the ideal solution for rapidly and cost-effectively, bringing fresh, new, exciting, and flavorful dairy products to consumers. For over twenty years Pladot has been designing, fabricating and installing miniaturized dairy processing plants that are rapidly deployable, minimally space consuming, and competitively priced. Pladot’s Mini Dairy systems literally bring sophisticated dairy product manufacturing to the consumer’s doorstep and are an exceptional solution for providing specialized distribution-sensitive dairy products to discerning customers. Pladot’s Mini Dairy systems are the solution for offering fresh, natural, innovative and gourmet dairy products without incurring expensive investments in manufacturing and distribution infrastructures that may otherwise be unsuited for lower volume specialized dairy processing.

Most importantly, Pladot brings to the table a total solution. Pladot plans, manufactures, integrates and assembles all Mini Dairy components into fully functioning processing facilities. Pladot engineers custom-tailor facilities to process smaller volumes of milk into an extensive range of sophisticated dairy products from flavored butters to specialty cheeses and crème yogurts. Pladot’s manufacturing specialists provide the necessary training, recipes and food technology expertise required to process a long list of Mini Dairy products. Pladot’s competitively priced and comprehensively designed dairy processing solution allows dairy product manufacturers to rapidly deploy localized small scale facilities that can supply products customized to consumer demand in target markets.



Cost Effective Manufacturing Solution

A complete dairy manufacturing facility – planned, manufactured and installed in one competitively priced package that includes dairy plant engineering know-how and processing expertise as well as guidance and consulting on subjects ranging from site selection to product recipes.

Rapidly Deployable Processing Facility

A Pladot Mini dairy can be manufactured, shipped, installed and prepared for processing in a very short time span. The markedly reduced implementation time from concept to initial processing permits rapid exploitation of localized consumer demand or specific niche markets.

Compact Design and Operation

The largest Pladot Mini Dairy configuration requires a mere 5000 Square Feet of manufacturing area including the production hall, cooling, incubation and machine rooms as well as ancillary spaces for a lab and office. Production savings are not only limited to physical space: Pladot’s largest processing system requires only 10 KW/h in electricity, just a quarter of a Gallon per hour of Diesel Fuel, 1800 Gallons of water per day and only 12 to 16 employees.

Targeted Processing

Pladot’s Mini Dairies are uniquely suited for processing specialized dairy foods such as ethnic Queso Blanco, crème yogurt, flavored dips and soft Quark recipes, Kaffir and other flavored milk drinks, gourmet butters, Labaneh and Feta and an endless variety of Ice Creams. To manufacture many of these products at centralized, large scale facilities would prove impractical from a business perspective.

Distribution Efficiency

Because Pladot Mini Dairies can be rapidly deployed, are cost effective to construct, take up limited space and need few resources and personnel to operate, they can be positioned near target markets and configured to process specific products according to local demand. Placing Pladot Mini Dairies in strategic market locations reduces distribution expenses and permits processors to supply super fresh, specialized and gourmet items to discerning customers.

Modularity, Flexibility, Scalability

Pladot’s Mini dairies are designed to accommodate scalability, modularity and rapid product diversification. As market demand shifts and as new products are introduced, Mini Dairies can be quickly adapted and equipped to supply new or changing requirements. Changes can be implemented on-site by a small team of technicians and space requirements provided by minimal additions to the currently installed facility. The diversity of products that can be processed by a Mini Dairy is equally echoed by the facility’s modularity and ability to adapt to changes in product strategy and consumer tastes.


Advantages of The MiniAdvantages of The MiniDairy ConceptDairy Concept




Equipment We SupplyEquipment We Supply

HTST Mini Pasteurizer

Raw Milk TankSeparator

Skim Milk Pump

Homogenizer

Butter ChurnProduction Tank

Processing Tank

At the core of Pladot’s Mini Dairy program is the company’s miniaturized dairy processing equipment line. Manufactured of high grade materials to exacting quality specs mandated by the ISO 9000, A-3, UL and CE Standards, Pladot’s equipment is backed by solid warranties and a commitment to excellent post-installation technical support. Pladot custom fabricates dairy equipment only after a rigorous process in which the customer’s manufacturing, financial and marketing requirements are carefully matched with technical considerations driving the design, production and supply of the equipment itself.

In addition to the variety of components required to process diversified dairy products, Pladot supplies ancillary equipment such as quality inspection and food lab instruments. Each Mini Dairy is supplied with a complete kit of spare parts and afull set of detailed technical manuals. Components are manufactured at Pladot’s plant usually within 120 days (ARO per dairy system), and are carefully packed, containerized and shipped to the customer. All of Pladot’s equipment and servicesare delivered duty-free to the US under the US-Israel Free Trade Agreement.




Equipment We SupplyEquipment We Supply(Continued)(Continued)

Typical Mini Dairy Equipment SummaryTypical Mini Dairy Equipment SummaryCooled & insulated raw milk storage tanks | Pasteurizer |Cream separator |Homogenizer | Insulated pasteurized milk storage tanksProduction tanks for cream and starter (lactic bacteria) |Butter churn | Milk filling and capping machine – for plastic or glass bottles

Insulated production tanks for Quark processing | Cheese bag draining trolleys | Cheese & yogurt cup filling & sealing machine Cheese vats and trays for soft cheese production | Cheese trays and baskets | Cheese cloth bags |Cheese baskets and trays draining

Trolley | Yogurt production insulated tanks | Milk & yogurt pump | Laboratory kit for bacteriological, fat, and milk control | Air compressor Cooling unit for cooling room – optional (390F ) | Heating system for incubator (900F – 1150F) | Water chiller (340F – 360F)

Culture Tank

Ice Cream Processor

Cup Filler

Cheese Mold Cart & TraysCheese Vat

Bottle Filler

Mixer

Cheese Bag Cart




Services We ProvideServices We Provide

Beyond the uniqueness of Pladot’s miniaturized processing model, the most singular nature of this concept is the integration of equipment manufacturing with knowledge-based services such as system design, implementation, training and processing know-how. Together, equipment and services are provided in an unmatched and otherwise unavailable package that, in financial terms, translates into an unusually cost-effective solution providing exceptional business value.

Planning & Requirements AnalysisPladot’s engineers and Mini Dairy specialists match equipment types andspecifications to the customer’s business and technical requirements. A customized Mini Dairy is diagramed and analyzed to insure a match to customer specifications in terms of planned products, milk quantity, space consideration, financial ability and other parameters.

Engineering & DesignPladot’s engineers and technicians custom design a proposed Mini Dairy and plot its data using sophisticated CAD tools. Concurrently, Pladot offers consulting and support to the customer in areas related to site selection, architecture, flow control, energy, as well as water and wastewater supply and removal.

Site & Facility Development300 Mini Dairy installations have endowed Pladot with a wealth of expertise on issues related to development of a Mini Dairy’s physical facility. Pladot engineers can, if required, work closely with building, health and business licensing authorities as ancillary consultants to the dairy customer.

Equipment Installation and InitiationPladot’s technicians can manage and/or assist in the installation and integration of the different Mini Dairy processing components. After the facility has been installed, Pladot’s experts initiate prototype production to insure all systems are functioning according to planned specifications. The Mini Dairy is delivered to its customer fine-tuned and ready for production.

Operational and Recipe Training One of the most important elements of Pladot’s Mini Dairy business package is the training Pladot provides to its customers. A week in Israel, at Pladot’s R&D Mini Dairy, and up to 14 days of on-site training, provide customers with the technical insight required to operate equipment and the food technology expertise to master a long list of dairy product recipes.



Gourmet Restaurant Supply

Bulk Deli Cheese


GoatCheese

CrèmeYogurts

Fancy Dips

Soft White(Quark)

Sour Cream



Products We Can MakeProducts We Can Make

The Pladot Mini Dairy is an excellent platform for processing a large variety of dairy delicacies, gourmet cheese, ethnic selections, yogurts, milk and flavored milks, dips, specialized butters, crème fraiche, ice cream, fresh cottage, farmers and cream cheeses and even French specialties.

Almost any requirement for a more specialized, fresh, distribution sensitive dairy product, is uniquely suited for processing at a Mini Dairy. Beyond purely retail oriented products, Mini Dairies are also an exceptional source for bulk cheese sold at Deli counters and gourmet cheese for restaurants that require the freshness and unique flavor attainable only through small batch processing.

FarmerCheese

GourmetIce Cream

GourmetButters

Cheese With Herbs

FetaLabbaneh


Technical SpecificationsTechnical Specifications

Product Mix & Quantities per Mini Dairy Size

Physical Properties per Mini Dairy Size

Typical Small Dairy Layout




Pladot is committed to supplying products that consistently exceed customer expectations in terms of quality and technical support.

Pladot markets its products through a worldwide network of specialists that provide close customer support and a continuous link to the manufacturer. Through this global business network, Pladot maintains a level of responsiveness and service that parallels the superb quality of the products themselves.

Pladot’s operations are driven first and foremost by an unwavering dedication to quality. Each and every one of Pladot’s operations are geared to provide customers with the best and most durable products possible. Each and every Pladot employee invests an added effort to insure his products excel in design, quality and value. Manufacturing processes are uniform, disciplined and synchronized, and are designed to achieve maximal customer satisfaction. Most importantly, as an ISO 9000 certified facility, Pladot’s commitment to quality is documented and established as a company-wide policy and way of life.

Quality StatementQuality Statement





Located in the Jezreel Valley in northern Israel, at the foot of the Gilboa Mountains, Kibbutz Ein Harod Meuhad is named for Gideon’s Spring (Harod in Hebrew) where God counseled Gideon before his battle with the Midianites. The Spring is located adjacent to the community and is a popular attraction for Judeo-Christian tourists.

Kibbutz Ein Harod Meuhad is a cooperative community and organization. Several hundred families live and work in the Kibbutz and mutually own the community’s assets, much like employee stock holders work in, and own a part of, their respective corporations.

Originally focused on Agroproduction, the Kibbutz has evolved into a multi-faceted business-driven entity in which a variety of industries contribute to the organization’s revenues. From sophisticated defense contracting, to amber-colored ultra quality Honey, Kibbutz Ein Harod Meuhad is a diversified and successful business entity managed and operated by members whose families descend from the country’s founding fathers.

The values of family, community, history and land set in lush valley vistas bordered by mountains, contribute to the resourcefulness, growth and success of Kibbutz Ein Harod Meuhad. Since its inception in the 1920’s, this community has not only spawned leadership and heroism but has established itself as a model for commercial success driven by creative investment and astute management.


A few Words About UsA few Words About Us

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