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Sycamore Process Engineering boosts production time for major UK cheese maker

Sycamore Process Engineering has completed a major upgrade project at Saputo, Davidstow, to install their largest CIP (clean in place) set to date – a system which allows the cheese maker a significantly reduced window for cleaning and additional flexibility on CIP cycles, giving an increase in production time.

Prior to the installation of the new CIP set, the team at Saputo completed a circa five to six hour CIP turnaround ahead of their normal production window. The new multi-tank, multi-channel system allows them to complete their CIP turnaround in less than four hours, dramatically reducing the cleaning window which, in turn, allows Saputo to continue making more of their award-winning cheeses, including Davidstow and Cathedral City.

Sycamore was successful in securing the project back in February 2020 just ahead of the pandemic and first lock down and were tasked with the design, build, and installation of a new CIP system. The process has improved operating efficiencies and hygiene, incorporates rinse and detergent tanks and is modular in construction of CIP delivery and return. With the new CIP sets multi-channel functionality, it also allows more items to be cleaned simultaneously giving production much more flexibility and options when planning cleaning schedules.

Paul Manning, Project Director at Sycamore Process Engineering, said: “We’re excited to finally be able to reveal that the cheese maker we’ve been working with is Saputo. The team at Sycamore has done a fantastic job and the new process equipment is working very well and as planned. Credit also goes to the team at Saputo for their patience and flexibility during what has been a difficult year with extra challenges. Commissioning of the new system is now complete; we have come out of this project with a great partnership with Saputo and are already working on and talking to them about the next projects on site.”

The initial design work was completed in early March 2020 followed by manufacturing and arrival on site of the new equipment during the summer of 2020. Work was able to continue during both lockdowns with increased focused on-site safety and social distancing measures. Change over and commissioning was successfully completed during a six-day shut down during the second UK national lockdown.

The existing footprint for the new CIP set was quite compact so our design team carefully considered the layout optimizing tanks sizes and equipment selection, keeping it efficient, without compromising maintenance access and serviceability of the equipment in the future. All feedback to date from the site wide team at Saputo has been positive and well received.

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