Quality meets convenience
The processed cheese industry in South Africa has been growing for years. Between 2019 and 2023 alone, sales of processed cheese rose by almost 30 per cent, and market researchers expect annual growth of around 2.6 to over 6 per cent in the coming years. This is serious competition for the medium-sized dairy company Ladismith Cheese. But the passionate natural cheese producers are rising to the challenge and want to offer consumers an attractive, healthier alternative to processed cheese: pre-cut, long-life natural cheese in attractive, consumer-friendly packaging.
Complex technology from a single source
In order to meet the high demands placed on perfectly packaged natural sliced cheese, a well-designed, high-performance production line with various components that all interlink automatically in harmony and perfection – from high-quality cutting to individual labelling. For economical, smooth operation, such a system must also be low-maintenance and easy to service. Everything from a single source: this was ultimately one of the key criteria for Ladismith’s decision to award Bizerba with this project.
- Founded: June 1999
- Headquarters: Ladismith, South Africa
- Distribution: Retail, wholesale, food industry
Increasing added value with natural cheese products
Ladismith Cheese was faced with the task of competing not only against established processed cheese producers, but also against competitors from within its own ranks, as other natural semi-hard sliced cheeses were entering the market at the same time. This meant that products were needed that were convincing in terms of quality, packaging and presentation and that were at least on a par with the competition. Only in this way could Ladismith Cheese price its natural sliced cheese products profitably and increase its added value.
Integration of external components
There were clear technical requirements: precise cutting, target weight, MAP packaging under a protective atmosphere, integrated metal detection and accurate labelling, with as little aste or yield loss as possible along the line. A consistently high level of quality across all product ranges was crucial. At the same time, the solution had to come from a single source and all components had to be fully integrated. The remote location of the site made this difficult, as only locally available packaging technology could be used previously. Ladismith Cheese therefore needed a partner who could supply and support a complete line and also reliably integrate third-party components.
Complete solution tops off addition
Ladismith Cheese initially approached Bizerba with the request for a cutting solution that could be connected to an existing thermoforming machine. However, during the qualification phase, it became apparent that a complete solution consisting of Bizerba and Intrama components was the better option for the company – both for budgetary reasons and due to the available space. Successful tests and demonstrations at Intrama and Bizerba confirmed this decision and convinced Ladismith Cheese, so that nothing stood in the way of installing the new production solution.
Compact dimensions, full performance
Finally, Bizerba implemented a customised, fully integrated production line measuring below ten metres in length, consisting of the A560 high-performance slicer with weighing function, an automatic product loading system from Bizerba and Intrama, and a thermoformer. A Bizerba line converger aligns the filled packages on the conveyor belt, and a metal detector checks for contamination. The final step is labelling with the GLM-Emaxx 50 price and product labelling system with weighing and labelling function. The entire production line is controlled and monitored live by the Bizerba BRAIN2 industrial software.
Working hand in hand for the best results
During implementation, the Bizerba team also successfully made minor customisations to the Intrama devices. Among other things, a checkweigher was integrated and the thermoforming machine was equipped with a mould and die configuration specially designed for larger packages with higher stacks of slices. Intrama and Bizerba provided comprehensive training to ensure the smooth commissioning of the new line.
Ladismith Cheese has now been working with the new production line for over seven months. The first successes are clearly visible: the natural cheese specialist has expanded its range to include product lines that were not previously available under the Ladismith Cheese brand. Overall, the investment is having a noticeable positive effect on processes, sales and market position. In addition to direct sales success, the new range of natural sliced cheese is also strengthening Ladismith Cheese's presence in both the retail and catering sectors.
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