ProNutri Dairy Foods — Operations Plan
The proposed processing facility will be constructed on a 5-hectare site in the George Industrial Area. The facility design follows international best practice for dairy manufacturing, incorporating clean-room processing environments, automated CIP (Clean-in-Place) systems, and segregated product flow to prevent cross-contamination.
Section 9 · Business Plan
Operations Plan
The proposed processing facility will be constructed on a 5-hectare site in the George Industrial Area. The facility design follows international best practice for dairy manufacturing, incorporating clean-room processing environments, automated CIP (Clean-in-Place) systems, and segregated product flow to prevent cross-contamination.
9.1 Processing Facility Layout
The proposed processing facility will be constructed on a 5-hectare site in the George Industrial Area. The facility design follows international best practice for dairy manufacturing, incorporating clean-room processing environments, automated CIP (Clean-in-Place) systems, and segregated product flow to prevent cross-contamination.
| Facility Area | Size (m²) | Function |
|---|---|---|
| Milk Receiving Hall | 800 | Raw milk intake, quality testing, initial cooling |
| Pasteurisation Area | 1,200 | HTST pasteurisation, homogenisation, separation |
| UHT Processing | 600 | Ultra-high temperature sterilisation and aseptic filling |
| Cheese Manufacturing | 1,500 | Cheese vats, pressing, aging rooms |
| Yoghurt & Fermentation | 800 | Fermentation tanks, flavouring, filling |
| Packaging Hall | 1,800 | Automated filling, labelling, case packing |
| Cold Storage | 2,000 | Refrigerated storage at 2-6°C |
| Dry Storage & Warehouse | 1,500 | Packaging materials, finished goods staging |
| Quality Control Laboratory | 300 | Microbiological and chemical testing |
| Offices & Amenities | 1,200 | Administration, staff facilities, training room |
| Total Built Area | 11,700 |
9.2 Production Capacity
| Parameter | Year 1 | Year 3 | Year 5 |
|---|---|---|---|
| Raw Milk Intake (litres/day) | 120,000 | 240,000 | 300,000 |
| Operating Days per Year | 330 | 340 | 350 |
| Annual Raw Milk Processed (m litres) | 39.6 | 81.6 | 105.0 |
| Capacity Utilisation | 65% | 78% | 90% |
| Product Yield (% of intake) | 92% | 94% | 95% |
9.3 Raw Milk Procurement Strategy
ProNutri Dairy will secure raw milk supply through a three-tier procurement strategy. The primary supply channel will consist of long-term off-take agreements (3-5 year contracts) with 15-20 commercial dairy farms within a 100km radius of George, providing approximately 70% of requirements. Secondary supply will be sourced through the Milk Producers’ Organisation (MPO) cooperative network, providing swing volume of approximately 20%. A strategic reserve of approximately 10% will be maintained through spot market purchases and potential acquisition of one or two dairy farms from Year 3 onwards.
Raw milk pricing will be negotiated on a cost-plus basis linked to the MPO reference price, with seasonal and quality-based adjustments. The Company will deploy mobile milk collection tankers equipped with real-time quality testing to ensure consistent raw material quality.
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