Gemak has successfully designed, manufactured, installed, and commissioned a state-of-the-art processing plant dedicated to producing plant-based yoghurts and dairy alternatives. In close collaboration with Meadow Foods, this milestone project—despite pandemic challenges—was delivered on time and on budget, exceeding all expectations.
The plant was built to produce The Collective’s innovative ‘Plant’ range—the UK’s first dairy-free, Greek-style yoghurt, crafted from a unique blend of oats, coconut, and rice.
A Groundbreaking Investment in Plant-Based Innovation
Established in 1992, Meadow Foods is the UK’s leading supplier of dairy ingredients to the food and drink industry. Their £4 million investment in this facility ensures segregated production for high-quality plant-based ingredients without compromising taste, texture, or quality.
Meanwhile, The Collective, known for their thick, creamy gourmet yoghurts, spearheaded the project, launching their first range of delicious plant-based yoghurts in January 2021.
Gemak’s Engineering Excellence
Selected as the process partner, Gemak leveraged its expertise in dairy and plant-based processing to design and deliver the project with precision and efficiency. Despite unprecedented challenges caused by the pandemic, Gemak’s innovative approach ensured a seamless execution.
A key factor in this success was Gemak’s 150,000 sq. ft. assembly facility, acquired in 2019 to complement its existing 200,000 sq. ft. manufacturing plant. This allowed:
- Full-scale pre-installation & testing of the entire plant, including pipework, cabling, and automation, at Gemak’s facility.
- 3D replication of the Meadow Foods floor plan within the Gemak assembly plant—a first in the industry.
- Reduced installation time by 8 weeks through pre-assembled, numbered, and systematically dismantled components.
This off-site assembly method makes Gemak the only manufacturer capable of delivering full factory installations, including electrical, ring mains, supports, and utilities, before on-site reassembly.
Industry Leaders Praise Gemak’s Contribution
Paul Jackson, Strategic Projects Director at Meadow Foods, said:
“We are excited to expand our plant-based product range and strengthen our portfolio. Gemak’s expertise was crucial in completing this project on time and within budget, overcoming pandemic-related challenges. We are extremely satisfied with their support and look forward to future collaborations.”
Ciaran Adam, Product Manager at The Collective, added:
“After two years of development, we are proud to launch the UK’s first plant-based Greek-style yoghurt. Gemak’s experience in yoghurt processing and high-quality work made them our preferred partner. Their team worked closely with us to deliver the project on time during unprecedented circumstances.”
Advanced Processing & Packaging Technology
The new plant-based processing system includes:
- Automatic multi-recipe blending unit for both dry and wet ingredients.
- High-efficiency pasteurisation, storage, and fermentation units.
- IBC filling station for bulk ingredient handling.
- Filltech double-indexing linear filling line for layered yoghurt pots, designed for automated diameter changeover.
- Raw and pasteurised CIP (Clean-in-Place) sets for hygiene and efficiency.
This facility is designed to produce a variety of plant-based products, including yoghurt, drinks, cream, sour cream, soft cheese, milk, custard, and other dairy alternatives.
A New Era for Plant-Based Manufacturing
Kursat Uysal, Director at Gemak UK & Filltech, concluded:
“This project required us to rethink installation methods due to pandemic restrictions. By assembling and testing the entire plant in our facility—including full pipework, electrical installation, and ring mains—we ensured rapid, precise on-site execution. We thank Meadow Foods and The Collective for their flexibility and trust in Gemak to deliver this cutting-edge process and packaging plant.”
As the plant-based food sector continues to grow, Gemak remains a leader in providing turnkey processing and packaging solutions, enabling dairy and alternative manufacturers to scale with confidence.
For more information on how we can support your business, contact our team today.
About Filltech
Filltech is a leading provider of filling and sealing machines, specialising in bespoke solutions for the dairy, food, and beverage industries. With over 25 years of expertise in the sector, Filltech delivers high-quality, automated filling systems designed to maximise efficiency, flexibility, and product consistency. Our selection includes cup filling machines, bottle filling machines, jar filling machines, bucket filling machines, and thermoform machines all tailored to meet your specific production needs. We offer both linear filling machines and rotary filling machines to match different production capacities and layouts, ensuring the right solution for every application. We fill a wide range of container types, including plastic cups, PET bottles, glass jars, HDPE bottles, aluminium cans, and buckets. Additionally, we supply tray packers and robotic palletisers to further streamline and automate your production process. At Filltech, we proudly serve a wide range of industries, including milk, yoghurt, spreads, ice cream, beverages, and honey. Our innovative filling and sealing machines are designed to meet the unique demands of each sector, delivering efficiency, reliability, and superior product quality. Whether you are involved in dairy, food, or beverage production, Filltech offers customised filling and sealing solutions to optimise your operations. Explore our range today and take your production to the next level.