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TurnkeyFeasibility studyAutomationCanada

From manual cheese production to an automated turnkey plant

For ADL in Canada, HSV Combi is developing a turnkey plant for the production of feta and Havarti. The approx. DKK 60 million project automates a previously manual production and brings process equipment, mold handling, electrical and automation together in one coherent solution.

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3D overview of the plant delivered to ADL in Canada.3D visualization · ongoing project
Feta and Havarti
Turnkey project
Approx. DKK 60 million
From manual to automated production

Starting point

A custom-developed cheese plant for feta and Havarti

ADL faced the challenge of lifting a predominantly manual cheese production to a modern, automated process. Production covers both feta and Havarti, which place different demands on whey drainage, mold filling, demolding, brining and mold handling.

The challenge could therefore not be solved with a standard machine. A complete solution was needed, developed around ADL's products, production methods and future needs.

Solution and responsibility

From feasibility study to turnkey delivery

The collaboration began with an extensive, paid feasibility study in which HSV Combi developed the technical basis for decision for the plant. The work covered process clarification, layout, P&IDs, 3D design, capacity calculations, equipment selection and planning of the complete production solution.

On that basis, HSV Combi was given responsibility for the turnkey project, including engineering, project management, manufacturing, electrical, automation, installation and commissioning. The project has a total value of approx. DKK 60 million.

Block mold washer, demolding line and CIP system.3D visualization · ongoing project
Block mold washer, demolding line and CIP (cleaning-in-place) system.

Equipment delivered

The delivered solution includes, among other things

  • Process solutions and machines for the production of feta and Havarti
  • Drainage belt and controlled whey drainage
  • Automatic portioning and mold filling
  • Custom-developed filling head
  • Feta demolding line with XY gantry system and pre-brining tank
  • Havarti demolding machine with demolding directly into brine
  • Large washer for block molds, round and square cheese molds and loaf molds
  • Automatic destacking and restacking of cheese molds
  • Automatic lid removal and replacement
  • Mold turning and automatic mold handling
  • Integrated mold conveyors between the process steps
  • Electrical installation and complete automation
  • Recipes and control of the production sequence
  • Overall integration of machines and process equipment
  • Installation, commissioning and handover
Feta demolding line with pre-brining and XY gantry system.3D visualization · ongoing project
Feta demolding line with pre-brining and XY gantry system.
Havarti demolding line for 1250 mm block molds.3D visualization · ongoing project
Havarti demolding line for 1250 mm block molds.
Mold filling line with XYZ gantry system in the ADL project.3D visualization · ongoing project
The mold filling line with XYZ gantry system as it is included in the ADL project.

Expected value

Value for ADL

The complete solution automates a production that was previously predominantly manual. Automatic portioning and mold filling are intended to provide higher weight accuracy, less product variation and a better basis for uniform cheese quality.

The custom-developed lines make it possible to handle both feta and Havarti in the same overall production environment, even though the two cheese types require different processes. Feta is handled through a demolding line with XY gantry system and pre-brining, while Havarti is demolded directly into brine.

Automatic handling of molds, lids and block molds reduces the heavy, repetitive manual tasks. At the same time, the large washer is intended to ensure uniform and documentable cleaning of several different mold types.

ADL gets one responsible partner for process equipment, mechanics, electrical, automation, installation and commissioning. This reduces the interfaces in the project and ensures that the individual machines are developed as parts of one complete production plant.

Process flow

  1. Process clarification
  2. Engineering and 3D
  3. Manufacturing
  4. Electrical and automation
  5. Installation
  6. Commissioning

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