At over 3 percent CAGR, the Middle East is the third fastest growing region in terms of dairy production and consumption . The company Almarai is a key player in this region and recently invested in new cup filling machines from Bosch Packaging Technology in order to strengthen its position and expand its business in the Middle Eastern region.
Almarai started its operation in the field of dairy production in 1977. With over 170.000 cows living on six farms, the dairy production exceeds one billion liters per year, making Almarai the region’s largest dairy company. Its popular product “Zabadi” is a set-style yogurt with a firm texture and is enjoyed plain or with added local ingredients. Due to the market’s rising demand for Zabadi the company looked for a filling solution that would increase production volume and efficiency while maintaining the product’s quality and taste.
High-speed yogurt filling made easy
The biggest challenge when filling set yogurt is that the product is highly liquid – comparable to water – at the time of dosing. Due to the rapid movement of the cups in a high-speed production environment, there is a higher risk of spilling the liquid product during the filling process. After filling and sealing the cups, the yogurt is given time to ferment. The so-called incubation process gives the set yogurt its firmer texture compared to other yogurt products, while making it highly nutritious and easier to digest.
Thanks to its reputation and experience in the field of hygienic filling and sealing machines for the dairy industry, Bosch subsidiary Ampack was the partner of choice for the project. Almarai invested in three inline cup filling machines to fill its Zabadi set yogurt. Equipped with a double index motion system, each unit reaches speeds of up to 38,000 cups per hour. Additionally, the machines come with a servo-driven vibration damping software, allowing a precise and reliable movement of the cups. As a result, they enable higher output capacities while keeping product waste to a minimum.
How does vibration damping work? See here:
Test environment active!
Next level efficiency
By investing in Bosch equipment, Almarai meets the stringent market requirements with regard to food safety. For example, the packaging material and all sensitive machine areas are treated chemical-free during the production in order to ensure high product quality. In addition, the product hopper and dosing-station are pressurized with sterile air to prevent product contamination. In terms of efficiency, the inline cup fillers are equipped with an intermediate cleaning option that is supported by an automatic rinsing bar. By the touch of a button, the dosing system can be cleaned automatically, while keeping the machine and its sensitive areas closed. This results in shorter cleaning times and increased production efficiency.
On top of that, Almarai appreciated the possibility to run extensive tests prior to the shipment of the machines. Almarai was confident that the right solution was designed to meet their specific needs and the three high-speed filling machines were installed ahead of schedule.
 Dairy in the Middle East and Africa, https://www.euromonitor.com/dairy-in-the-middle-east-and-africa/report
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