southwest cheese co. llc - edclc• 220 tankers of milk/day • 32 truckloads of cheese/day • 13...

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Page 1: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

Southwest Cheese LLC

1

Page 2: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

Who is SWC?: Southwest Cheese Company is a Joint Venture. The partners are:

50%-Milk Members

Members of Greater

Southwest Milk Agency

(GSA)

DFA GSA is responsible for : -Milk Supply

Select

Zia

50%-Glanbia plc

Glanbia plc

Glanbia is responsible for: -Operations -Marketing -R&D

Page 3: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

Dairy Farmers of America (DFA)

• Largest U.S milk marketer

• Formed in 1998 combining several existing milk coops

• Services 19,000+ dairies across 48 states

• SWC serviced by Southwest region

Page 4: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

Select Milk Producers

• Markets 6 Billion lbs of milk annually

• Formed in 1994

• Services 87 dairies in Texas, New Mexico and Southwest

Page 5: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

Glanbia- World Wide

Page 6: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

Glanbia Foods USA Footprint Glanbia Foods

ẋ Twin Falls, ID- Cheese Plant ẋ Richfield, ID- Cheese Plant ẋ Gooding, ID- Cheese/Whey Plant ẋ Blackfoot, ID- Cheese Plant

Glanbia Nutritionals * Springfield, MO- Blending Plant * Corona, CA- Aseptic Solutions * Sioux Falls, SD- Flax Plant * Madison, WI- Sales Office * Carlsbad, CA- Seltzer, Premix Blends

x

Performance Nutrition o Boca Raton, FL- Pre workout o Aurora, IL- Protein Blending

Joint Venture ẋ Clovis, NM- (Southwest Cheese) Cheese/Whey

Plant

x x x

x

Page 7: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

The Strategy for SWC • Joint Venture:

– Glanbia and Milk Member: clear rights, responsibilities and legal agreements regarding Milk Supply, Sales, Operations and Finance

• Operational Strategy:

– Economy of scale, low cost, high quality, utilizing the Glanbia Performance System GPS

– 640 pound & 40 pound cheese products – WPC 80 and WPI Whey products – Long-term (20 years) milk supply agreement

Page 8: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

SWC Milk Supply •There are 65 dairies producing 9 M lbs of Milk (150,000 cows) per day in Curry & Roosevelt County, this is within a 25 mile radius of the plant. •Milk Growth in 2013 for the area is expected to contract due to drought conditions •Average farm size 2,250 cows in production

Page 9: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

U.S Milk Supply Data: March, 2013

Page 10: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

Milk Utilization in TX & NM 2013 – Milk Distribution

-SWC 25% of Overall Milk Utilization -SWC 50% of Overall Milk used for Cheese

Page 11: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

Begin expansion:

10.5M lbs/day

Exceeding Design capacity

First milk processed 10/4/2005

Plant at design capacity: 6.8M

lbs/day

Plant expansion complete –

10.5 M lbs of milk/day

Discuss plant expansion to 10.5 M lbs of milk per day

SWC Growth Timeline

Site Selection

Ground Breaking

WPI Expansion

Value-add Project -Permeate

Milk Milestone:

4 Billion lbs/annum!

Page 12: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

SWC Throughput • Original capacity 2.4B lbs.

• Expansion capacity 3.8B lbs. • Over 4 Billion lbs. of milk

processed in 2012 and in 2013!

• SWC produces roughly 10% of US market share of American Style cheese.

• Produced 440 Million lbs. of

cheese in 2013- Export 50 M lbs

• Over 12% of cheese produced was exported to 28 different countries, primarily Mexico

Page 13: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

SWC - The Plant • $300 million investment-

– Original build: $200M – Expansion: $100M

• 220 Tankers of Milk/day

• 32 truckloads of cheese/day

• 13 truckloads of whey powder/wk

• Approximately 375 employees

• Process Water Use - 350k/day

• Effluent Water – 1.2 Million gallons/day

Page 14: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

SWC Produces • Milk Processed: 11 Million lbs/day

• Cheese (40’s/640’s): 8.3 Million lbs/week – 40’s: 5.3 Million lbs/week – 640’s: 3.0 Million lbs/week

• WPC 80: 330 Thousand/week

• WPI: 170 Thousand/week

• Permeate: 1.1 Million gal/wk

• Water: 900k gal/day

Page 15: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

SWC - Critical Success Factors

People – attract, train and retain well-trained, skilled, competent and highly motivated employees

Efficiency- low cost productivity, operate at capacity, waste minimization- GPS

Non-Negotiables: Safety – provide a safe and secure work

environment Quality - Products produced consistently. Sustainability- to meet long-term commitments -

raw milk, energy, water, wastewater Housekeeping- “Always audit ready”

Page 16: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

Glanbia Performance System- GPS

• Example: SWC Reduction of Lost Opportunity- Revenue (Fines, Downgrade, Waste, Process)

Guaranteed to succeed, but… its not easy …. detail, tenacity, rigor are REQUIRED!

It’s all about changing thinking and behavior – weaving a culture focused on Zero Losses where everyone, everyday learns & improves something

Page 17: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

Safety- Incidence Reduction A 40% reduction in 1 year!

• Safety reduction driven daily actions utilizing Behavioral Based Safety, Risk Predictions, Early Management and Progressive Maintenance

• Safety owned by “Everyone, Everyday”

Page 18: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

Sustainability (Water, Gas) Net water generator of 900,000 gal/day!

• Biogas Usage: • 5% of total plant needs

Page 19: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

Quality- “Voice of the Customer” Cheese: 38% Improvement in 2 years!

• Whey Plant quality performance excellent- 4 years in a row. Slight increase (9 complaints total 2013)- New customer ASPAC

• Cheese Overall complaints/100 shipments improved 15% YOY, 38% vs 2012 • SWC 40 complaints/100 shipments steady performance and favorable to target of 1.00 • SWC 640 complaints/100 shipments 23% improvement YOY, 51% improvement vs. 2012.

Page 20: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

Perennial Award Winning Cheese

US Cheese Contest: 2009- Gold 2011- Silver 2013- Gold and Bronze World Cheese Contest: 2008- Gold and Bronze 2010- Gold, Silver, and Bronze 2012- Bronze 2014- Bronze 2012 Customer Bulk Cheese Supplier of the year

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Page 21: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

Supplying the World w/ Food

55 Million lbs. of cheese in 28 Countries in 2013!

Page 25: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

Key Stakeholders • Community

• Donations in excess of $300k+ to: Clovis Schools Foundation ($100k/annum), United Way, PRMC ($35k), Hartley House, Clovis Music Festival, Others

• Suppliers

• Dairy Industry

• Employees • 380+ People • Average $20+/hr

Page 26: Southwest Cheese Co. LLC - EDCLC• 220 Tankers of Milk/day • 32 truckloads of cheese/day • 13 truckloads of whey powder/wk • Approximately 375 employees • Process Water Use

SWC: A Partnership for Growth and Sustainability

Questions?