Great plains builder: to keep pace with growing sales, Anderson Erickson restructures its plants and adds 25,000 sq. ft - Anderson Erickson Dairy Co - includes related articles - 1993 Processor of the Year - Cover Story

Dairy Foods, Nov, 1993 by Jack Mans

Two of the carton machines are dedicated to small cross-section cartons running products primarily for schools. One of these is a four-lane machine running 240 cartons per minute, while the other is a two-lane unit running 150 per minute.

The third machine--AE's most sophisticated carton filler--runs pints and quarts at 200 cartons per minute. Equipped with a programmable logic controller (PLC) that monitors and regulates machine operation, the filler also features a CRT that enables the operator to easily communicate with the filler and change operating conditions for different products and carton sizes. This system also includes data acquisition capabilities and provides troubleshooting and maintenance information.

This machine incorporates a controlled environment enclosure and high-efficiency particulate air (HEPA) filters to maintain clean conditions in the filling and sealing area. It also includes a dedicated cleaning and sanitizing system that cleans the machine at set times and also can be set to spray sanitizing solution inside the chamber periodically during operation.

The fourth and oldest carton filler at AE runs 80 half-gallons per minute in one lane. In spite of its age, the machine has a modern feature: A system to attach plastic spouts to the cartons was installed last year.

Spouts are delivered from a hopper installed next to the machine by a cleated conveyor that drops them into the spout feeder. This single-files the spouts in the proper orientation down a chute entering the filler. The spout, with the cap attached, is pushed through a die-cut opening in the carton, and the flange around the base of the spout is ultrasonically sealed to the interior of the carton. The carton then is filled and sealed just like a non-spouted carton. AE uses the spout on cartons of juice and other value-added products.

CULTURED PRODUCTS

Although cultured products comprise only about 10% of total shipments, AE produces a wide variety, including cottage cheese, yogurt, sour cream and dips. The dairy's most noteworthy cultured product item is its Old Fashioned cottage cheese, which has no stabilizers and must be hand filled. AE also produces the more typical cottage cheese that contains stabilizers which is processed and packaged the same way as the Old Fashioned.

Yogurt, sour cream and dips all are processed and packaged with the same equipment.

AE has always been recognized in its marketing areas for its superb quality. In addition, the dairy recently won the "Sweepstakes Award" from Master Dairies Inc. for the excellence of all of its products. The major plant addition and restructuring of its operations now underway will certainly strengthen AE's outstanding reputation.

Plant Facts

Name: Anderson Erickson Dairy Co. Location: Des Moines, Iowa Products: Milk, juice, cottage cheese, yogurt, sour cream, dips Brand name: Anderson Erickson Site 25 acres Total 97,000 sq. ft. Processing/packaging. 19,000 sq. ft. Cooler 25,000 sq. ft. Other: (office, etc.) 53,000 sq. ft.