58 | PRODUCTION AFFCO Horotiu T T Hugh de Lacy Future proofing with major upgrades AFFCO, owned by the Nelson-based Talley’s group, has spent “tens of millions,” Trevor says, upgrading its 12 plants around New Zealand. “Apart from the obvious improvements in facilities, the changes are aimed at giving the workforce of 510 people a sense of identity with and pride in their workplace…” A multi-million-dollar investment in its meat-processing plants nationwide has seen significant input into AFFCO’s freezing works in Horotiu in the Waikato. The on-going Horotiu upgrades have included the Beef Carton Lidding Project which set out to improve the appearance of the company’s packaging and improve the downstream automation system. “We’ve installed a new carton buffer and carton palletiser, and that’s allowed us to redeploy a number of staff to other parts of the operation where we were short. “This helped with efficiencies and savings on costs,” Horotiu Plant manager Trevor Bennett says. “Another project was the building of a new calf shed to replace the old holding yards, ensuring that the calves are kept warm and dry while awaiting processing. “The old yards had passed their use-by date. “Last year we also commissioned a new 8MW wood pellet boiler, replacing a gaspowered one. “The wood pellets are supplied by Nature’s Flame in Taupo, creating a more environmentally positive facility and reducing our carbon footprint,” says Trevor, who’s been with AFFCO for 21 years. AFFCO, owned by the Nelson-based Talley’s group, has spent “tens of millions,” Trevor says, upgrading its 12 plants around New Zealand that export lamb, beef and allied products to more than 80 countries round the world, along with dairy, seafood and vegetable products that fall under the Talley’s umbrella. Horotiu is the original AFFCO plant, a single-species beef facility, opened in 1916 in the middle of World War One, and it has since been extensively re-built to make it the largest-capacity beef plant in the group. It also processes calves during the season, and is a fully approved halal slaughter facility operating both rendering and blood plants and producing the full range of beef cuts and offals. “The AFFCO directors have committed big money on upgrading all our plants over the last few years, including revamping the cold stores here in Horotiu, replacing the cold stores ceiling and roof and introducing the Beef Lidding Project to the boning room,” Trevor says. “And we’re not finished here yet; the projects already approved by the directors kick off in April with a new ammonia plant room that powers our chillers and freezers, and then the installation of a new 10,000-carton blast freezer. “Apart from the obvious improvements in facilities, the changes undertaken at Horotiu are aimed at giving the workforce of 510 people a sense of identity with and pride in their workplace, as well as building the plant’s reputation as the leading facility of its type in the country. “It’s also aimed at giving our staff a sense of job security in a topsy-turvy world where the wars in Iran and Ukraine have upset the normal flow of business, and the old and formerly reliable structures of international trade have been turned on their head,” he says. info@pulseengineering.co.nz | 07 849 3785 PRODUCTS DESIGNED FOR SAFETY, EFFICIENCY AND PERFORMANCE • Conveyor Design, Fabrication & Installation • Specialist in Hygenic Processing Plant Fabrication • General Stainless Steel Fabrication & Installation • Custom Design & 3D Solid Modelling Proud label supplier to AFFCO Horotiu We are a trusted supplier to Affco for over 15 years, and are leaders in meat labelling solutions for the New Zealand industry • Compliant reliable & consistent products • Solutions for processing plants right through to retail • Linerless wraps for premium presentation • Commitment to environmental sustainability Contact our label experts on 03 349 5299 or mcc.christchurch@mcclabel.com Proud to support AFFCO Horotiu Sales • Service • Training 0800 696 858 info@multivac.co.nz multivac.com/nz MULTIVAC New Zealand We cover the whole process chain with our innovative solutions for processing and packaging Fresh Meat and Meat products.
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