Production

Nutribén® Factory

Discover our modern infant formulas factory, a benchmark in innovation and technology in the industry and possibly one of the most modern, best-equipped infant formulas factories in the world.

Located in Meco (Madrid), our facilities have a 8,500 m2 gross floor area to allow us to control the production process of our milk from beginning to end, being able to guarantee our consumers and prescribers the highest standards of quality and safety.

The entire range of Nutribén® milk is manufactured and produced in these facilities, standard formulas, hydrolyzed, soy-free, lactose-free, etc. Up to 9,300 tonnes of milk powder per year at the moment and with the possibility of increasing further up to 12,000 tonnes per year.

Automation, standardization and traceability

Our production process is fully automated and controlled in real time, so that the processes are always performed in the same way. In addition, when all the products are made at the same factory, their homogeneity is guaranteed, always maintaining the same quality, safety and properties.

Production process

1

Reception of ingredients and storage

All materials received at our unloading bays must have been previously approved to meet the high standards of quality and safety established by Nutribén®. To access the facilities all personnel must comply with a dress, cleaning and disinfection protocol that ensures optimal maintenance of hygienic conditions.

2

Preparation and mixing

The high quality and technology of the equipment used, such as tanks, mixers and pasteurizers, guarantee maximum quality and microbiological safety, and constant product homogeneity.

After the wet mixing process of the ingredients that make up the formula, it is pasteurized and cooled to ensure the correct microbiological and functional conditions. This liquid milk is stored while waiting to move onto the next process that will turn it into milk powder.

All the information necessary to control the traceability of the production is stored in computer systems. Information such as batches of raw materials used, quantities dosed, pasteurization, homogenization and cooling parameters is recorded.

3

Evaporation and drying

Liquid milk is transformed into milk powder in the drying tower. Here the milk enters the top through spray nozzles, which create millions of micro-drops. The water from these micro-drops of milk evaporates when it comes into contact with a flow of hot air, and these fall to the bottom of the tower in the form of "specks" of milk powder.

The many factors and variables involved in this process make it very complex. Thanks to the great automation of the drying tower and its quality and design, we can ensure a perfect final result for our milk powder.

At the end of the drying process two "fluidized beds" are obtained, the first one obtains the powdered milk with the desired humidity, and the second cools the resulting product and packages it quickly to maintain optimal conditions.

4

Filling containers

Before being filled, the containers are sanitized with short wave ultraviolet light to ensure that there will be no recontamination of the milk once packaged. The containers are then transported to a hygienic room with a controlled atmosphere in which two robots insert the scoops into the containers. Then the filling takes place: each container must receive the exact product quantity.

The tins are hermetically sealed immediately after filling, ensuring the quality and safety of the product inside. Later the tins are coded by laser technology, the plastic lids are fitted and they are packed in groups of 6 ready for distribution.

The whole packaging line is controlled by a computer system that captures all the real time information related to the process, for total control of production traceability.

5

Storage and logistics

Once the milk has been packaged, a robot packs them on pallets and an advanced pallet transport system communicates the milk factory with our Logistics Centre, so that within a few minutes of being packed, the product is stored and ready for distribution.

Quality and safety are our reason for being, so the whole line of storage and distribution is controlled by a MES system (real time production control system) that captures the online information of the machines. This information is also sent to the SAP management system which closes the information cycle necessary to ensure the traceability of production.

Facilities

Nutribén® facilities occupy 18,000 m2 in Madrid; Equipped with the latest technology, they were opened in 2009, improving our production capacity and quality to support the international growth of our brands.

Milk Factory

  • 8500 m2 plant.
  • Annual production: 9.300 tons.
  • The highest standards of quality, security and hygiene.
  • Opened in 2014 with an investment of €30 million.
  • Tetrapack technological guarantee.
  • Produces the entire range of infant milk (Regular and special).
  • Packaging capacity of 3,600 tins/hour.
  • 400 and 800 gr. formats.
  • Lithographed. metal tins.
  • Automated logistics warehouses that assures the customer the best traceability and service in all orders.

Baby food factory

  • Production process through thermal hydrolysis, a natural process that improves the finished product .
  • 2900 m2 plant.
  • Annual production: 6,500 tons.
  • The highest standards of quality, security and hygiene.
  • Packaging formats: 250, 300 and 600 gr. Samples: 14, 20, 45, 48 gr.
  • Automated management of the raw material warehouse to increase product safety.
  • 100% CIP (Clean in place) automated cleaning throughout the production line.
  • Metal detector before packaging.
  • Packaged in an inert atmosphere.
  • Bags weighed to ensure EC regulations on actual content.
  • 100% verification of bar codes

Potitos® Factory

  • 2328 m2 plant.
  • Annual production: 6,300 tons.
  • The highest standards of quality, security and hygiene.
  • Packaging formats: 130, 200 and 250 gr.
  • Automated management of the raw material warehouse to increase product safety.
  • 100% CIP (Clean in place) automated cleaning throughout the production line.
  • Automatic detector of foreign bodies in empty bottles.
  • Vacuum control (Coverpop) to control food safety.
  • Internal 0.7, 1.2 or 1.5 mm sieves according to variety + 1,5mm.
  • FCP and batch encoders to prevent tampering.
  • 100% verification of bar codes.