Nestlé is undertaking a major upgrade at its plant dedicated to producing Nescafé Frothy Coffee sachets. This initiative includes constructing a state-of-the-art mixing plant and installing two advanced high-tech packing lines, with a combined output capability of up to 60,000 frothy coffee sachets per hour.
The brand-new mixing plant, representing a £17.5 million investment, is designed to enhance efficiency by employing the latest equipment and adhering to modern design standards, ultimately aiming for higher product quality.
This four-storey facility will reduce heavy lifting by 80% thanks to a novel system that handles ingredients in larger bags, significantly minimizing manual labor and improving overall accuracy in production.
Additionally, the plant is set to boost operational efficiency and recipe accuracy, aligning with the factory’s long-term master plan for increased volumes.
Nestlé is also investing £10.7 million in two new packing lines to replace older equipment. One of these new lines will have the ability to produce 60,000 sachets per hour using “cutting-edge” technology, which ensures a smoother and more efficient flow of items. Furthermore, these lines will utilize innovative packaging materials like MONO PP laminate, making them fully recyclable and reinforcing Nestlé’s sustainability goals.
Richard Watson, CEO of Nestlé UK & Ireland, remarked: “We are very proud of our British manufacturing and this investment reflects the great work being done by our teams to position the UK as a market with significant manufacturing expertise and capability.”
“The Dalston investment is a prime example of how we’re investing in the future of the British food and drink industry – modernising our operations and supporting local jobs, driving growth opportunities and being more sustainable.”
Ian Pipes, Nestlé Dalston factory manager, stated: “We are delighted to have secured this investment which marks a significant step forward for our Dalston site. By upgrading our facilities with the latest technology, we’re not only improving product quality, but also creating a more sustainable and supportive environment for our teams.”
These upgrades at Dalston aim to deliver superior products to consumers while minimizing environmental impact and enhancing site efficiency.
Nestlé Dalston has been a key player in producing Nescafé Frothy Coffee products since 1962.
Recognized globally as a Centre of Excellence for Frothy Coffee, the factory produces popular items such as Nescafé Cappuccino, Latte, Coffee Mate, and even Starbucks’ range of Latte products.
Initially established in Cumbria to capitalize on the proximity to dairy farms, the factory produces an astounding 25 million Nescafé Cappuccino and Frothy Coffee sachets each week, using sustainably sourced fresh milk.
Since 2010, Nestlé has partnered with First Milk to promote responsible farming practices, enhance animal welfare, and safeguard Cumbria’s natural landscape, ensuring that the premium fresh milk used in Frothy Coffee products is not just high-quality but also sustainably produced.