Así funciona una planta de procesamiento de leche - TvAgro por Juan Gonzalo Angel Restrepo — Transcript

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1. 0:18We are in the milk receiving area,
2. 0:20where our entire process begins.
3. 0:24Initially, we collect the milk, our
4. 0:26primary raw material, which is then
5. 0:28transported by vehicle to the company.
6. 0:32Upon arrival at the company, different
7. 0:34physical and chemical analyses are
8. 0:36performed on the product to ensure it
9. 0:38meets the proper conditions for
10. 0:40processing. Within these analyses, we
11. 0:43conduct acidity tests, cryoscopy, among
12. 0:46others. Finally, the quality department
13. 0:49helps us determine if the milk meets
14. 0:51the characteristics required for entry.
15. 0:56Subsequently, the vehicle is unloaded
16. 0:58using two 30,000 L/h pumps through
17. 1:01pipes and a plate cooler, which lowers
18. 1:03the temperature to 6 degrees before it
19. 1:06is stored as raw milk in a silo. After
20. 1:11storage as raw milk in the silo, we
21. 1:13begin the thermization process, our
22. 1:16first thermal process, where the milk
23. 1:18is heated to 68ºC for 20 seconds
24. 1:20before moving to the cooling stage. In
25. 1:25this process, we also separate the fat
26. 1:27to achieve the required level according
27. 1:30to the type of milk we need to package
28. 1:32or the next process. It is then stored
29. 1:36in in-process product silos. From there
30. 1:40, we take samples to maintain full
31. 1:42traceability of our initial raw
32. 1:44material, which is, as mentioned, the
33. 1:47milk. Hello, TV Agro friends, my name
34. 1:53is Natalia Estrada. Welcome to Milk
35. 1:55Receiving at Pomar. Our milk receiving
36. 1:59process starts at the gate. At the gate
37. 2:01, we verify that the tankers have all
38. 2:03their security seals intact. We move to
39. 2:06the scale where the number of liters
40. 2:09contained in the tanker is measured.
41. 2:13Right after the scale, we move to our
42. 2:16discharge and sampling line, where our
43. 2:18operators take a sample of the contents
44. 2:21of the tankers. We then take this
45. 2:25sample to the laboratory, where they
46. 2:28approve whether or not we can unload
47. 2:30the milk brought from our farms. Once
48. 2:35the laboratory clears the milk for
49. 2:37unloading, it passes through a cold
50. 2:40curtain and is stored in our storage
51. 2:42tanks. After completing our milk
52. 2:59receiving process, we continue with the
53. 3:01thermization process. There, the
54. 3:05initial heat treatment is applied to
55. 3:08the product, heating it to 68ºC for 20
56. 3:10seconds followed by cooling. A type of
57. 3:15stabilizer is added to avoid stability
58. 3:17issues in the following process. It is
59. 3:21stored in in-process storage silos as
60. 3:23thermized milk, where the respective
61. 3:25analyses are performed, such as fat
62. 3:27content, cryoscopy, pH, and
63. 3:29organoleptic testing, among others.
64. 3:33Following the thermization process, we
65. 3:35have the ultra-pasteurization process,
66. 3:37from which it exits via a centrifugal
67. 3:39pump and enters the
68. 3:40ultra-pasteurization equipment. The
69. 3:44initial process in the
70. 3:45ultra-pasteurization equipment is the
71. 3:48homogenization process, where fat
72. 3:50particles are reduced to prevent
73. 3:52separation over time. Subsequently, we
74. 3:56begin a heating process. We have two
75. 4:00machines, an 18,000 L/h unit and a
76. 4:0216,000 L/h unit, which bring the milk
77. 4:04to a temperature of 140 ° C, plus or
78. 4:07minus one, for 4 seconds. Following
79. 4:11these 4 seconds, we have the cooling
80. 4:14process where we bring the product to
81. 4:1728–30 ° C for packaging. At the end
82. 4:21of the ultra-pasteurization process,
83. 4:24checks are performed before starting
84. 4:27packaging, such as temperature controls
85. 4:31, homogenization controls, and others
86. 4:34to ensure the quality of our products.
87. 4:46Hello, friends of TV Agro, how are you?
88. 4:48My name is Daisy Quintero. Today I want
89. 4:51to invite you into our plant. I am a
90. 4:55production supervisor. At this moment,
91. 5:00our plant has three aseptic packaging
92. 5:04machines, A3, two dedicated to
93. 5:07packaging white milk in different sizes
94. 5:12, such as 900 ml, 946 ml, up to 1000 ml
95. 5:16. We have one A3 connected to a machine
96. 5:21called the One Hit. This one is
97. 5:24dedicated only to special products such
98. 5:29as almond beverages in two sizes: 1000
99. 5:33ml and 900 ml. We also have two
100. 5:38flexible packaging machines. What does
101. 5:41flexible mean? That they are in bags.
102. 5:45With these, we have different sizes
103. 5:47ranging from 200 ml up to 1000 ml. We
104. 5:52package three types of milk: whole,
105. 5:54skim, and semi-skimmed. We have
106. 5:59personnel trained to operate the
107. 6:02machines. They are responsible for the
108. 6:05integrity of the packaging, ensuring
109. 6:07they come out properly sealed. They
110. 6:11must guarantee batch identification and
111. 6:13expiration dates on the product, as
112. 6:16well as verifying compliance with the
113. 6:19weight per reference. These tasks must
114. 6:22be performed every half hour to ensure
115. 6:25a safe product for the consumer. Beyond
116. 6:29the qualified personnel in the aseptic
117. 6:32section, we also have staff in the
118. 6:35packaging area who work as a team to
119. 6:38ensure the product is well-stacked,
120. 6:40clean, and properly palletized for
121. 6:43delivery to the logistics department.
122. 6:47It is very important to mention that
123. 6:49the personnel who work with us must
124. 6:51comply with good manufacturing
125. 6:52practices, which, what does that mean?
126. 6:55They must have an excellent personal
127. 6:58appearance, ranging from proper hairnet
128. 7:01placement, short fingernails, to
129. 7:04thorough boot disinfection every time
130. 7:07they enter the areas. They must keep
131. 7:11their uniforms clean and cannot wear
132. 7:14things like watches, chains, or
133. 7:17piercings, as these can represent a
134. 7:19physical risk to the product.
135. 7:35Continuing with this tour, it is
136. 7:36important to mention the disinfection
137. 7:38treatment of the packaging material
138. 7:40used to contain the product. We use
139. 7:43sterilization by means of hydrogen
140. 7:46peroxide. Afterward, it passes through
141. 7:48a temperature of 140 to 150ºC. Then it
142. 7:52passes through a hot air knife at over
143. 7:54200ºC to completely eliminate any
144. 7:56hydrogen peroxide residue, since it
145. 7:58must not remain inside the product.
146. 8:02Additionally, laboratory tests are
147. 8:04performed with strips where we check
148. 8:06the parts per million of hydrogen
149. 8:07peroxide in the product, which must not
150. 8:09exceed 0.5 parts per million. As my
151. 8:14colleague mentioned, the packaging
152. 8:16process continues, where the product is
153. 8:18transported via a conveyor belt and
154. 8:20reaches accumulators that give the
155. 8:23distribution equipment time in case of
156. 8:25any failure. Afterward, we go to the
157. 8:28cappers, which apply the cap according
158. 8:31to the type of product and the type of
159. 8:33container in which the product is being
160. 8:35packaged. Next, we have the cartoning
161. 8:39process, where we have a cartoning
162. 8:41machine on each line that groups them
163. 8:44by 12 or 24, depending on the type of
164. 8:46product, and then we move on to
165. 8:48stacking or palletizing. After that, we
166. 8:53go to the storage warehouse, where the
167. 8:55product is kept for distribution. Our
168. 8:59company is ISO 22,000 certified and has
169. 9:02the Invima sanitary permit, which is
170. 9:04the standard handled in food
171. 9:06manufacturing companies. To meet these
172. 9:11requirements, we have implemented an
173. 9:13entire quality and food safety
174. 9:15management system on each of our lines,
175. 9:17through which an annual audit is
176. 9:19conducted, presented in several phases.
177. 9:23One of the phases is a plant visit, a
178. 9:25physical audit as such, and a
179. 9:27traceability audit to keep control of
180. 9:30the documentation for all products. And
181. 9:34we also have the entire management and
182. 9:36control system for operational
183. 9:40prerequisite programs. We are now at
184. 9:53the final part of our tour, where our
185. 9:54team handles everything related to
186. 9:56palletizing, marking the pallets, and
187. 9:58the final traceability of the product.
188. 10:02Afterward, the product is palletized
189. 10:04and delivered to the quarantine storage
190. 10:06warehouse, where it stays for a time
191. 10:08estimated by the quality control
192. 10:10department before being distributed to
193. 10:12our final customers or our distributors
194. 10:14. My job here is palletizing, keeping
195. 10:26an eye on the cartoners......and the
196. 10:31sealing, ensuring there are no missing
197. 10:33caps, so that the product is perfectly
198. 10:35ready for human consumption. And well,
199. 10:39I arrive at 6 in the morning and
200. 10:42palletize five pallets. My colleagues
201. 10:45here also palletize five pallets each.
202. 10:48We also keep an eye on the dates and
203. 10:50the cleanliness of the plant and all
204. 10:53that.
205. 11:01Hello friends at Teagro, my name is
206. 11:03José Luis Restrepo, and I am the
207. 11:05production supervisor for the Pomar UHT
208. 11:07line plant. We are currently at the
209. 11:10final section of the distribution
210. 11:12equipment. In this area, we are
211. 11:15responsible for checking and ensuring
212. 11:17the integrity of the cardboard boxes,
213. 11:20making sure no flaps are left open, and
214. 11:22we guarantee the labeling of each one.
215. 11:25Here, boxes of 12 units are made, and
216. 11:28pallets of 80 boxes are prepared to be
217. 11:31handed over to the logistics department
218. 11:34. Around 260,000 liters are packed
219. 11:38daily in this plant. Once delivered to
220. 11:43the logistics area, it enters the
221. 11:45quarantine zone where quality control
222. 11:47releases the product, and it is then
223. 11:49dispatched to the different
224. 11:50distribution warehouses of our clients.
225. 12:02El Pomar is made up of 495 employees,
226. 12:05495 families that make this work
227. 12:07possible, but besides that, we also
228. 12:10have 225 dairy farmers, which are also
229. 12:13225 families that are part of this
230. 12:16process. We support nearly 90%of our
231. 12:21employment, which is generated between
232. 12:24Cajica and Paquirá, by local people.
233. 12:28We have a career plan where people can
234. 12:30join, and as the company grows, we
235. 12:32provide them with opportunities for
236. 12:34both training and advancement within
237. 12:36the company. 55%of our management team
238. 12:40are women, and 45%of all our employees
239. 12:43are women. We work with local people
240. 12:47who are proud of the plant, proud of
241. 12:49the region, and very proud of our dairy
242. 12:52origins. Friends of TV Agro, I want to
243. 12:55end this tour by inviting you to
244. 12:57consume dairy products, Pomar products.
245. 13:00Remember that dairy products are a good
246. 13:02source of calcium and protein; they
247. 13:04should be part of our daily diet. Um,
248. 13:07we hope to keep growing hand in hand
249. 13:09with our cattle ranchers, continue
250. 13:10supporting the Colombian countryside,
251. 13:12and we look forward to seeing you here
252. 13:14again.