Gemak UK completes advanced whey processing facility for South Caernarfon Creameries

UK – Gemak UK, a leading dairy solutions provider, has completed a state-of-the-art whey, milk, and cream processing facility for South Caernarfon Creameries (SCC) in Wales, setting new benchmarks in dairy processing efficiency and sustainability. 

The facility, part of SCC’s US$18.7 million expansion to increase cheese production from 15,000 to 23,000 tons annually, includes a whey processing and concentration unit capable of handling 600 tons of milk and whey concentrate daily. 

According to Gemak, the plant achieves a 30% total solids concentration in whey, a notable improvement over traditional systems. 

This efficiency reduces energy consumption and supports SCC’s net-zero water goals, reinforcing its position in the global cheese market. 

The Welsh Government contributed US$6.2 million to the initiative, highlighting its regional economic importance.

“We were excited to partner with SCC and are thrilled to have met all key performance indicators, marking a milestone in UK whey processing,” Kursat Uysal, director of Gemak UK, stated.

The facility also features a cheese Clean-in-Place (CIP) unit and storage silos, designed to enhance operational precision and hygiene. 

Alan Wyn Jones, managing director of SCC, noted, “This facility allows us to maximize whey’s value, turning a byproduct into a high-quality ingredient for global markets.”

A report by Dairy Processing Handbook emphasizes whey’s growing importance, with global output reaching 180 million tons in 2013, containing 1.5 million tons of protein. 

The new facility employs advanced membrane filtration to isolate proteins, catering to nutritional markets like sports and infant nutrition. 

This aligns with industry trends, as whey protein is valued for its nutritional benefits, including high-gelling beta-lactoglobulin and lactoferrin.

Gemak’s expertise in thermal processing and automation ensured the project’s completion within a tight timeline, despite challenges posed by the dairy industry’s competitive landscape.

The facility’s design minimizes environmental impact, addressing concerns raised in a 2023 study by Buchanan, which noted whey’s environmental risks if untreated. 

By valorizing whey, SCC avoids waste and enhances sustainability.

The completion of Project Dragon positions SCC as Wales’ largest farmer-owned dairy co-op and strengthens Gemak’s reputation in innovative dairy solutions. 

Industry observers anticipate the facility will drive export growth, meeting rising demand for whey-based products worldwide.

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