A new packet butter machine has transformed production at Ballyragget writes Glanbia’s Butter Production Manager, Michael Curry

Since the 1970s, the team in Ballyragget have been producing packet butter on two consumer packet butter lines, namely 227g & 454g. In 2015, a review of the packet butter lines was carried out which concluded that the 227g line, including case packing and palletisation process, was close to end of life and would soon become obsolete and unfit for purpose. Specifically, the 227g line did not meet pack quality and presentation expectations.

Since 2015, production has continued despite the shortcomings of the 227g line and ongoing reliability performance issues. From 2016, production volumes were small due to exiting the export packet butter business, but growth on the 227g line over the last two years from 600 tons PA to 2,000 tons PA has been welcomed. Planned increase in volumes over the next four years is mainly driven by TGF and additional private label business on the 227g line.

The installation of a new ‘Benhil’ 227g packet butter machine including inline X-Ray and check weighing equipment has made a world of difference. The new machine has replaced the previous 44-year-old ½ lb packet butter machine and associated check-weigher, X-Ray and conveying lines. With installation complete, we’ve produced the first commercial product to everyone’s satisfaction! Well done and thanks to project manager Declan Dunne and butter process manager Martin Boran for delivering a great project within budget and one week ahead of schedule.

We are currently seeking approval for funding to complete phase 2 of our packet butter investment programme which would see the replacement of the case packer, inline wrapping and palletisation. The benefits of this investment would mean a 100% increase in throughput, the ability to pack butter in a range of sizes from 200g to 500g, meet planned volume growth and replace old and obsolete equipment.