Our dairy plant is not a copy of any other plant, it was constructed according to an individual project.
Everything was taken into account: location, local production and technical requirements, requirements to ready products, requirements to product sales.
— Georg Dückinghaus, head of the Trubatec GmbH (Ahlen, Germany)
Journey of the milk
It is hard to imagine any meal without milk. Have you ever wondered what a difficult journey milk has to travel in order to reach our table?
This journey is much more interesting than it may seem at first glance. We will tell you how well-organized this process is at the Nalchik dairy plant.
This journey is much more interesting than it may seem at first glance. We will tell you how well-organized this process is at the Nalchik dairy plant.
The milk comes from the farms located in pollution-free mountainous areas. Once a cow is milked, the milk is cooled to 10C and collected by milk tankers of the Nalchik dairy plant equipped with a milk cooling system.
Once the laboratory staff confirms the high quality of the milk and the absence of harmful additives and pathogenic bacteria, the milk goes to separators and then to cooled raw milk storage tanks.
This is where the milk starts its journey through the plant's systems. Part of the milk goes to modern technological units – bactofuge separators, where the milk gets cleaned of bacteria and spores that cause souring, while retaining the most valuable and wholesome elements.
The milk proceeds to cream separators, which divide the milk into cream and skimmed milk. Later, it makes it possible to get the necessary fat content in the product by mixing cream and skimmed milk. This is how we get milk with a specified fat content, for example, 2.5% and 3.2%, or cream with a fat content of 10% or 20%.
Thanks to modern homogenizers we can get the desired consistency and homogeneity of the product and improve its taste, while preserving all useful properties at the same time. Then the milk goes to pasteurizers, plate-like heat exchanging units. The Nalchik dairy plant has the most modern and powerful heat exchangers. When passing through the plates of the pasteurizer, the milk gets instantly heated up to 85C and then instantly cooled down. Such heat treatment causes minimal damage to the taste and properties of the milk. It is important to note that the milk makes this journey through the milk pipelines of the plant in sterile aseptic conditions, without being in any contact with the air.
The part of the milk to be sold in cans and cartons goes to the filling line. In order to make it easier for the consumers, the milk at the Nalchik dairy plant is bottled in different types of packaging. The plant has the traditional and reputable equipment for packing in Pure-Pak cartons. These cartons are made up of several protective layers, each of them having its own function: cardboard provides stiffness and light opacity, foil enhances barrier properties, polyethylene layers provide high quality sealing and impermeability. Thus, the milk in this package is protected from exposure to the greatest possible extent and can retain its properties for a long time.
Nalchik dairy plant was one of the first plants in Russia to start packing milk in convenient plastic cans, which are now very common in Europe. For this purpose, there is an innovative extrusion blow machine installed at the plant. Bottling in our own cans is not only beneficial and convenient for consumers, but it also allows us to guarantee the highest quality of packaging.
The other part of the milk is processed. There are formulations strictly followed by product engineers for each of the 200 products. In total, the plant consists of six departments for production and packaging of milk, processed cheeses, soft and semi-hard cheeses, sour cream, fermented milk products, cottage cheese and butter.
The best
production solutions
We accept no compromise when it comes to quality. From the very beginning we set a high standard and took an extremely responsible approach towards selecting the equipment. After a careful examination and analysis, we commissioned the German company Trubatec, one of the leading European companies in construction of dairy plants, to design the project. Its specialists paid special attention to the choice of the equipment. As a result, the plant's lines are now equipped with the best technical solutions from Germany, France, Italy, the USA, Denmark, Holland and Russia.
Many factors were taken into account during the project development, such as specific features of local production, location, environmental friendliness, easy equipment maintenance, and many more.
Our departments feature lines for the production and packaging of milk, melted cheese, soft and semi-hard cheese, sour cream, fermented milk products, cottage cheese and butter. The best equipment from the world's leading manufacturers (GEA, GRASSO, BEKUM, SERAC, PACK LINE, ELOPACK, THIMONIER, GALDI, APV) demonstrates flawless performance.
The quality of our products must be impeccable, this is why we monitor every stage of production, from the reception of raw materials to the delivery of end products to the stores. The plant has an accredited microbiological laboratory that ensures compliance with all technological, sanitary and hygienic standards.
In order to remain the leader of the industry and to guarantee the highest quality of products and packaging to our consumers, we have chosen and installed innovative extrusion blow equipment that helps us produce modern and convenient cans. The plant was the first to start producing such cans at its premises.
Our dairy plant is very special; it is not a copy of another dairy plant.
Our plant is our PRIDE.
Our plant is our PRIDE.
Strict quality control
Upon reception at the dairy plant, each container with milk undergoes a strict laboratory control that includes physical, chemical, microbiological and organoleptic analyses. Once the laboratory staff confirms the high quality of the milk and the absence of harmful additives and pathogenic bacteria, the milk goes to cleaning separators and further to cooled raw milk storage tanks.
The microbiological laboratory is the scientific centre of the plant. Our laboratory, which has been officially accredited by the State Sanitary and Epidemiological Service, is equipped with advanced technical solutions, such as high-sensitivity microscopes, cutting-edge analysers, computerized milk sorting systems etc.
Only a limited number of employees have access to this department. In order to get to the laboratory, each of them has to go through a special transition room and change into a clean working uniform.
Qualified laboratory specialists must check every stage of production process, from the reception of raw materials to the release of end products.
Upon reception at the plant, each container with milk undergoes a thorough microbiological, physical, chemical and organoleptic analysis. Even a slight deviation from the plant's requirements can result in elimination of the tank with the milk and its exclusion from production.
The laboratory is responsible for compliance with all hygienic and sanitary standards in the production, ensuring cleanliness of all units and production lines.
Finished products also undergo a mandatory inspection. Highly sensitive equipment is used in this process, since the content, percentage of fat and number of beneficial bacteria indicated on the label must correspond to those of the product.
One of the mandatory daily procedures organized by the laboratory is tasting the samples of each batch of end products. To ensure impartiality, tasting is done not only by the laboratory assistants, but also by the representatives of other company departments. If one of the tasters is not satisfied with the taste or quality of any product, the whole batch is removed from the market.
CERTIFICATES
HALAL
Certificate of conformity
Халяль-ППТ-СМР. СО-2011
CERTIFICATES
HALAL
Certificate of conformity
Халяль-ППТ-СМР. СО-2011
Products
Production
© Nalchik dairy plant, 2015-2018