Since the 1980s, Fonterra & RML Machinery Ltd have cultivated a partnership rooted in mutual growth and technological advancement. What began with RML providing essential components for Fonterra’s operations has evolved into a comprehensive collaboration that continues to drive efficiency and innovation within the Australian and New Zealand dairy industry.
In the early days, RML played a supporting role, supplying Fonterra with high-quality components that helped streamline manufacturing processes. Fast forward to today, and RML has become a crucial partner, delivering world-class production automation machinery that elevates Fonterra’s operational capabilities to new heights. To date, RML has supplied Fonterra with over 60 advanced production automation machinery solutions across New Zealand and Australia, spanning a broad spectrum of dairy packaging and processing needs.
The RML portfolio includes case packing machines, cartoning equipment, automated guided vehicles (AGVs), palletising systems, conveyor solutions, tub lidding, can capping machines, and butter sheet wrappers. These sophisticated systems have been customised to handle a broad range of Fonterra’s products, from cream cheese, cheese blocks, slices, and shredded cheeses to milk cartons and bottles of varying sizes, as well as butter in sheets, pats, blocks, and many other dairy products! RML is also involved in the processing of milk for Fonterra, which is used for milk powder, butter, and cheese. This is achieved by providing world-class components, including clean-in-place (CIP) nozzles, reception swivel strainers, drier winches, isolation valves, and more
This technological partnership has significantly transformed Fonterra’s manufacturing landscape. The machinery provided by RML enables Fonterra’s workforce to focus on higher-value tasks, freeing human potential and reducing manual labour. The automation solutions improve efficiency and yield substantial cost savings, collectively amounting to millions of dollars in operational savings over the years.
The impact of this collaboration extends beyond financial metrics. By integrating the innovative machinery designed and built by RML, Fonterra maintains its reputation for quality and reliability, ensuring its products reach consumers with consistency and excellence. This partnership exemplifies how cutting-edge automation can foster growth and resilience within the dairy sector. While RML has forged collaborations with numerous New Zealand dairy companies, the Fonterra partnership stands out as the longest and most profound. It reflects a shared commitment to pushing technological boundaries and supporting the growth of New Zealand’s dairy industry.
As both companies look to the future, our ongoing collaboration promises continued innovation, efficiency, and success — a testament to the strength of our enduring partnership.
Transforming Fonterra Whareroa Operations
One notable example of the enduring relationship between RML and Fonterra is the upgrade of their Whareroa site in New Zealand in 2008, which was an impressive showcase of the engineering prowess of RML and commitment to delivering customised, high-performance machinery.
Fonterra sought to replace an aging, slower piece of equipment that no longer met their rigorous standards for efficiency and reliability. Their confidence in the expertise of RML led to the deployment of a custom-designed Wraparound Case Packer to pack 20kg cheese blocks, an advanced solution meticulously engineered to enhance productivity and product integrity.
This custom case packer features an innovative collar inserter module, which snugly fits around the outer edge of cheese blocks, forming an ultra-strong container designed to withstand the rigours of storage. This optimisation ensures maximum yield from 20kg blocks, enabling Fonterra to deliver top-quality retail products while minimising waste.
Additionally, RML engineered a specialised infeed and outfeed system, precisely customised to operate seamlessly within the plant’s confined space. Recognising the need for versatility, the system can invert blocks and boxes during transfer, all while maintaining safety and efficiency standards, an essential feature in a fast-paced dairy environment. This project exemplified how RML isn’t just a machinery supplier, but a trusted partner immersed in delivering customised, world-class production automation solutions.
The work RML has done at Fonterra Whareroa also consists of a bath loading and unloading system for mozzarella buckets as all mozzarella at Whareroa is run through RML bath loading and unloading machinery and then conveyed out for case packing. These are just a few of the projects over a 40+ year relationship, showcasing the dedication of RML to empowering Fonterra and other industry leaders with reliable, innovative, and customised production technology.
What does the future hold?
As Fonterra continues to grow its operations, RML remains committed to being a key partner in future-proofing its manufacturing and production by providing world-class automation systems. By integrating cutting-edge robotics and industry-leading control systems into its products, RML ensures that products are not only efficient but also adaptable to the evolving needs of the market. As we look to the future, we remain committed to exploring new technologies and enhancing our product range to better serve Fonterra and the rest of our customer base. Our journey, which began over four decades ago, showcases a relentless drive for innovation and a passion for engineering solutions that empower businesses worldwide. Now that we have moved into our brand-new purpose-built facility in Hamilton, we are excited for the future, with innovation at the forefront of our business.
If you are looking to improve your production processes, then Production Automation Solutions designed and built by RML will provide your company with greater productivity, which will help the push towards this goal.
