Initially capacity was four million units a year, however, looking ahead, BV Dairy commissioned equipment that would allow production of sixteen million units per annum.

As demand on the new line increased the decision to automate was reached and BV Dairy consulted UPM Conveyors to design a system to transfer bottles through each process stage from the filling in a high care area to capping, metal detection, labelling and finally to pack flow wrapping and palletising for which UPM used 3D solid modelling design software for creating a 3D digital protype using the design visualisation and simulation of product to ensure efficient product flow through the high care area and to packing.

UPM liaised with all the main equipment suppliers to integrate the conveyors which involved testing the system at UPM prior to installation as it was necessary to effect the side transfer of product from each section of the system to ensure the elimination of any potential jamming and product damage.

Mark Jeanes, engineering project controller at BV Dairy, expressed total satisfaction with UPM for its cooperation in managing the project with minimum effect on production. UPM Conveyors has been awarded an order for phase two of the project.