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Wiseman Dairies is one of the UK's largest milk processing companies and operates from five major processing dairies in Aberdeen, East Kilbride, Glasgow, Manchester and Droitwich Spa.
The company did receive a boost, however, when they obtained the contract to supply milk to Tesco in mid-2006, with a contract to Sainsbury's soon after.
The company also invested in expansion of older facilities, such as their dairy at Droitwich Spa, to supply the additional volumes of liquid milk required for their contracts. However, capacity requirements have meant that the plant's output needs to be increased again. During 2005–06, expansion was on the cards once more due to the magnitude of the Tesco and Sainsbury's milk supply contracts. Architectural input by BDP was given in order to control the external form as the dairy was to sit on former farmland surrounded on two sides by natural woodland; in some instances this resulted in modifications to plant layouts inside the building.
All internal areas were designed around the production sequence, from raw milk intake through to the despatch of processed finished milk. At full capacity the facility (prior to expansion) produces up to 10 million litres per week of milk in addition to an extensive cream filling facility which produces up to 15 million cream pots per annum. The building is clad in flat composite external panels supplied by Kingspan, laid vertically to minimise weather staining and the need for flashings. External areas, totalling 45,000m², comprise a 250-person car park, milk reception canopy, travelling vehicle wash, fuel filling station and 90 electrical hook-up positions for refrigerated distribution vehicles.
The trapezoidal roof panels and architectural wall panels feature coated steel sheets sandwiching a fire-rated urethane core, with a food-safe internal surface especially developed for dairies, food processing plants and similar hygiene applications. The factory-made composite panels were fully integrated into the structural steel framework; forming a total building envelope with excellent thermal insulation properties, extremely low air leakage and no cold bridges or condensation traps.
In 2003 conveyor specialist Isoma developed a real-time simulation pack, which replicates the total production of any plant and can be used to analyse machinery efficiency.
Robert Wiseman Dairies has used the simulator to analyse real-time production data at the Droitwich facility.
When designing the Droitwich site, Wiseman allowed Isoma the license to include any other features that could be shown to enhance operations.


The Droitwich site is also equipped with DLog industrial PC units to automate the processing and bottling of milk. Robert Wiseman Dairies has struck a deal to supply Tesco with another 35m litres of milk a year, but said volume gains with the Co-operative Group had been offset by the retailer's decision to source ‘value’ milk from another supplier.
While bulk cream prices remained high, this has been offset by “customer price reductions, increased costs and an increase in the amount paid for raw milk supplies”, added Wiseman.
Operational efficienciesOn the plus side, Wiseman has made considerable progress with initiatives to reduce electricity, gas and water use.“Further to the installation of a reverse osmosis plant at Bridgwater, we are now able to recover a significant proportion of the water utilised on site. Get FREE access to authoritative breaking news, videos, podcasts, webinars and white papers.
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Even when the loss of several important milk contracts in 2005 from ASDA and Morrison's indicated a possible down turn in profits and redundancies, Wiseman's were still investing in their facilities. The £40m project was started in October 1999 and completed in May 2001 when production commenced with two filling lines.
In 2002, a further £7m was invested in the dairy to increase capacity to 350 million litres of milk produced per annum with the installation of the fourth and fifth filling lines.
The building was designed by the Building Design Practice (BDP) alongside technical personnel from Robert Wiseman’s and Tetra Pak.
In a first for the UK, the dairy was constructed from the very start incorporating a plastic blow moulding bottle plant attached to a Filling Hall and Sleeve Labelling mezzanines. Raw milk is offloaded at external tanker reception and then piped into a series of ten 250,000l silos from where it is passed into processing before being piped directly to the finished milk tanks prior to being supplied to the filling machines in the filling hall. Europe’s largest roofing and cladding contractor, Briggs, successfully used the latest Oktopus GA-V panel-lifting machine from Dedicated Sales and Services of Droitwich, to install 9,000m of Kingspan insulated panels for a new building. Isoma was able to input real-time information on downtime at the plant and could then change various parameters on the simulation to identify optimum plant production.


Isoma proposed key features for the site, such as automatically adjustable conveyor guide rails (bottle width), vision inspection and on-line rejection and three-way full bottle conveyor division to a mixture of trolley packers and shrink wrappers.
The price of high density polyethylene, which is used in plastic milk bottles, was up 7% and diesel was up 16% year-on-year, it claimed. During the period we also undertook a ?1.2m spend on upgrading the refrigeration plant and an associated heat pump at our Manchester dairy. We have ever designed food package, Electronic Pictorial for food companies in Australia, England and Turkey.
The design was able to create the optimum relationship between the various process rooms, filling and despatch areas.
This elevation houses the main administrative offices for the milk production with distribution and blow moulding housed opposite. Isoma was responsible for the total system line control at Droitwich and designed, manufactured and integrated conveyor systems in the filling hall and in Alpla Plastics on-site plastic milk container blow moulding facility. Installed on trolley packers, the units are very reliable and are regularly cleaned with water and chemical agents. Further to this expenditure, the plant will reduce the use of electricity, gas and water in operating the refrigeration. However, it was “disappointing” that to date this material was not providing a cost advantage, said bosses.
City reactionPanmure Gordon analyst Damian McNeela said he was encouraged by the new Tesco business and expected Wiseman to make cost savings to recover its lost margins over the next 12 to 18 months. However, Shore Capital analyst Clive Black said his “expectations for Bridgwater may not now be met although we note business wins for Wiseman from Tesco, which may assist the filling of the plant”.



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