Birch & Waite's new food manufacturing plant includes a number of Australian first processing and packaging technologies.
On 25 August, Birch & Waite opened the doors of its new facility to dignitaries, business partners and the media, who were invited to tour the plant designed by engineering company RMR Process.
The official opening ceremony was conducted by the Hon. Craig Laundy, Assistant Minister for Industry, Innovation and Science.
The site has been designed to allow for expansion as well as the anticipated increase in food safety standards. Agile manufacturing design allows for flexibility and specialisation, which could include robotic automation when volumes demand it.
The company predicts the new facility will drive over $20 million in growth for the business, which has averaged over 15 per cent cumulative growth per annum over the last 16 years.
A key area of production focus at the Revesby site is Birch & Waite's aged care health range – thickened liquid health products for those suffering from dysphagia, a disorder that causes difficulty, or inability to swallow.
The dysphagia products are processed using breakthrough technology: the first industrial Steriflow Shaker Retort system in the southern hemisphere.
The new processing technology, with a much reduced cycle time and lower cook temperatures compared to conventional retort systems, enables higher vitamin retention, lower salt use, gives food a better look and taste, as well as a longer shelf life.
“We realised that as well as developing products with good flavours, there is a clear need in the health care sector for a new, more palatable product to support the hydration and nutrition requirements of people with dysphagia. The new technology at Revesby has made this possible,” Birch & Waite general manager David Charles said.
The dysphagia products are packed in cups on a high-speed G Mondini Trove filling line using MAP technology.
The packaging was approved by Arthritis Australia and health professionals to ensure an easy-open experience for patients. The cup includes a grip indentation to make it easy to hold and to control when removing the lid. another feature is the easily visible, large pull tab and perforations to assist with grasp, reducing the requirement for fine motor control.
The company is also making premium batch products for consumers and professional chefs in sachets at the new facility.
“High pH sauces that contain fresh ingredients will keep their full flavour, nutritional value and freshness thanks to the quick thermal cooking process it allows. The end results are products that taste as if a chef has just created them.”
Another first of its kind line in the facility is a high-speed stick sachet FFS packing line for salad dressings that get inserted within a bag or bowl of fresh salad. The sachet pack's design enables the coding ink to be printed within the neck seal, so there is no food contact. The sachet also has an internal seam, preventing any possibility of contamination build up on pack exterior. A tear-notch in the neck allows for easy-opening and the narrow neck is shaped for easy dispensing.
Birch & Waite is a proprietary company wholly owned by two of the company's directors, Willi Schultheiss and Peter Flick.
The family-owned company already employs over 100 staff at its Marrickville factory, and the new site at Revesby will create up to 45 full time jobs.
“We are very happy with the way this has come together and Revesby will be a great benefit to Birch & Waite in the future,” Flick told launch attendees.
Schultheiss said: “The new factory opening marks an exciting stage in the history of Birch & Waite.
“Peter Taitoko and his team from RMR have been very innovative in their design and project management to deliver this project in a timely manner and affordable price.”
