2012 Fabulous Food Plant Photo Gallery
Commonwealth Dairy was chosen as Food Engineering’s 2012 Fabulous Food Plant. A partnership between US entrepreneurs and German investors is helping retailers meet demand for Greek yogurt with store-brand options.
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Green, amber and red lights on mix-proof valves’ control tops provide an at-a-glance status report on whether a valve is open, closed, or experiencing problems.
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A 6 oz. single-serving cup of Greek yogurt.
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The fermentation room is the most sensitive area of a yogurt plant. Frequent sampling and lab testing deliver quality assurance and a safeguard against wasted batches. Source: Tobias Gelston.
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The packaging area requires manual inputs, though automation will minimize them in the future. Source: Tobias Gelston.
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A clean-room zone in the yogurt fillers minimizes contamination risk and helps push shelf life to 60 days without preservatives. Source: Tobias Gelston.
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Maintenance Manager Daniel Frommel accesses a burned-out fluorescent tool in the dairy’s walkable ceiling area. Light fixtures, piping and equipment not needed on the production floor are isolated in the interstitial area above the ceiling and below the roof, improving plant hygiene. Source: Kevin T. Higgins.
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Push water for filler line evacuation is pasteurized in a UV system, eliminating the energy requirements of thermal pasteurization. Sensors monitor turbidity and UV intensity (foreground), while a mass flow meter (background) regulates water flow rate. Source: Tobias Gelston.
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Colored control-top lights provide at-a-glance status reports on mix-proof valves: green for open and amber for closed; a red light triggers a maintenance call. Source: Tobias Gelston.
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Benjamin Johnson (left) and Shambaugh’s Paul Meyers Jr. review the dairy’s yogurt packaging options, including a dual-chamber cup. Source: Kevin T. Higgins
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Raw milk receiving is the only area where swing connections are used to alter fluid flow. The rest of liquid handling is controlled by mix-proof valves. Source: Kevin T. Higgins
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Goof-proof color codes guide operators using HMIs: green boxes denote active equipment, while blue boxes highlight next-step options, including shutdown. Source: Kevin T. Higgins
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The search for flat land in Vermont turned up a buried automobile graveyard, requiring removal in 61 dumpsters. Source: Shambaugh & Son LP