/ Production Automation Machinery

Bag-in-Box Palletising and Conveying

CUSTOMER:

The Tatua Co-operative Dairy Company Limited

PRODUCT:

Filling & Bag Loading Integration; Extensive Conveying System; Centralised Palletising & Labelling; Track & Trace Control System

MODEL:

RATE:

Solution

Challenge

The Tatua Co-operative Dairy Company Limited approached us with an ambitious plan to significantly expand their cream production capability by building a new facility alongside their existing plant.

The project was highly complex, requiring a complete end-of-line system designed from scratch while the physical building did not yet exist. The solution needed to manage product from the filling stage in the pipes through to a fully wrapped, labelled pallet.

Key challenges included:

Designing a complex, modular system within a 6-month window before plant completion.
Handling product flow across five distinct sub-projects within a single overall system.
Integrating end-to-end track & trace to maintain product throughput, full traceability, and a single source of truth for all production line data.

Solution

We delivered a complete, turnkey end-of-line solution that seamlessly connects Tatua’s process from filling to final dispatch.

Working through an intensive 6-month design phase with weekly stakeholder alignment, we prototyped, tested, and validated key components before full production to guarantee reliability and performance.

The integrated solution features:

Filling & Bag Loading Integration: Streamlined handling as product exits the fillers directly into cases.
Extensive Conveying System: Hundreds of meters of customised conveyor networks that merge product streams cleanly and efficiently.
Centralised Palletising & Labelling: Automated collation, palletising, labelling, and wrapping of finished cases, making them ready for immediate dispatch to the end customer.
Track & Trace Control System: Full integration providing centralised data visibility, robust product flow management, and absolute traceability at every point along the line.

Through close collaboration, we delivered a complex, highly customised automation project on time and on budget, transforming Tatua’s high-capacity cream production line into a seamless, modern operation.

Ashley Bowen

Senior Automation Systems Engineer

Nemesys

RML have an amazing team of people. They were easy to work with and were happy to assist with any problems we encountered during the design and commissioning process.

Ashley Bowen

Senior Automation Systems Engineer

Nemesys

Sefton Pease

Project Manager

Tekplas

We’ve been so impressed by the level of service and quality of machinery that RML have built for us. With such an efficient machine, we’ve had no problem keeping up with production times and demands.

Sefton Pease

Project Manager

Tekplas

Will Rouse

Senior Engineering Project Manager

Fonterra – Edgecumbe

Working with RML on an innovative solution was straightforward. Their in-house expertise in all aspects of the design and build added value to the project delivery process and made some tough challenges easier to overcome.

Will Rouse

Senior Engineering Project Manager

Fonterra – Edgecumbe

Dale Pritchard

Factory Manager

MacLab

Our experience working with RML has been positive. We feel we received value for our investment.

Dale Pritchard

Factory Manager

MacLab

Graham Adler

General Manager

SNPshot Technologies

The machine provided by RML has to date, resulted in consistent high-quality product for SNPshot Technologies and guaranteed production costs.

Graham Adler

General Manager

SNPshot Technologies

Aaron Rowe

Continuous Improvement & Maintenance Engineering Manager

Comvita

We saw a 30% increase in line speed and output as a result of the RML equipment

Aaron Rowe

Continuous Improvement & Maintenance Engineering Manager

Comvita

Robbie Breen

Site Operations Manager

Oceania Dairy Limited

The trust and reliance that has grown from this project has us achieving numnbers we previously did not think would be possible. We will be searching for opportunities to collaborate with RML in future.

Robbie Breen

Site Operations Manager

Oceania Dairy Limited

Matt Freeman

Managing Director

Moondarra

Our integrated, advanced operation ensures the best quality cream cheese is produced consistently.

Matt Freeman

Managing Director

Moondarra

Brian Ryles-Smith

Group Technical Manager

Wilmar Sugar

It was an opportunity to increase the packing line automation, with labour savings offsetting the capital costs.

Brian Ryles-Smith

Group Technical Manager

Wilmar Sugar

Daniel Exton

R&D Project Manager

Gallagher

RML worked with us to understand our requirements and designed a solution to suit our needs. RML delivered an automated system to service two moulding machines producing the Gallagher Ring Top Posts.

Daniel Exton

R&D Project Manager

Gallagher

John Alexander

Solutions & Field Service Leader

Pentair

We set RML a challenge, design and build a new butter packing machine for a challenging application. RML produced a smart and effective solution that exceeded our expectations.

John Alexander

Solutions & Field Service Leader

Pentair

Hamish Roberts

General Manager - Operations

Greenmount Foods

Ongoing service and support is important to us. RML knew this and I am pleased to say we are not disappointed. I have and will continue to recommend RML to others in our industry based on our experience