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Production Cycle
Modern Automated Production Cycle — Cleanliness, Precision, and Control
At LLC "Cheese Factory No. 1", we operate a fully closed-loop production system built on Industry 4.0 principles. This means that every stage of cheese production is automated, digitized, and monitored with minimal human involvement.
Production Stages
1. Milk Reception and Preparation
Raw milk is delivered directly into sealed storage tanks, where it undergoes:
Milk is never exposed to air or open space — it moves through a closed system of sanitary milk pipelines.
- automatic filtration
- cooling to the optimal temperature,
- and inline laboratory analysis (fat content, acidity, density) via real-time sensors.
Milk is never exposed to air or open space — it moves through a closed system of sanitary milk pipelines.
2. Pasteurization
The milk is gently pasteurized at 62–72°C for 15–30 seconds using automated systems.
Temperature conditions are continuously monitored by sensors and logged in the production journal.
Temperature conditions are continuously monitored by sensors and logged in the production journal.
3. Addition of Starter Cultures and Enzymes
A precise dosing system adds the exact amount of:
Automation ensures accuracy and consistency, eliminating human error and guaranteeing uniform taste and texture.
- lactic acid cultures (starter),
- rennet (either natural or microbiological).
Automation ensures accuracy and consistency, eliminating human error and guaranteeing uniform taste and texture.
4. Curd Formation and Cutting
In the cheese vat, under PLC-system control, the milk forms a curd.
A robotic agitator then delicately cuts the curd into grains of specific size, with strict control over:
A robotic agitator then delicately cuts the curd into grains of specific size, with strict control over:
- stirring speed,
- temperature,
- and curd setting time.
5. Whey Separation and Curd Washing
Whey is automatically drained into a separate waste module.
The remaining curd is washed and prepared for molding
The remaining curd is washed and prepared for molding
6. Pressing and Molding
The cheese curd is transferred into automatic molds, where it is pressed into cheese wheels under controlled pressure.
Sensors monitor moisture levels, curd density, and residual whey content to ensure consistency.
Sensors monitor moisture levels, curd density, and residual whey content to ensure consistency.
7. Salting
Formed cheese wheels are moved to brine baths with an automated brine saturation system.
Time and salt concentration are regulated by a SCADA-based control system for optimal flavor and preservation.
Time and salt concentration are regulated by a SCADA-based control system for optimal flavor and preservation.
8. Aging
Cheeses are aged in climate-controlled chambers equipped with:
All batch data — including production date, chamber ID, parameters, and status — are logged in a digital system.
- automated temperature and humidity regulation,
- a micro-ventilation system.
All batch data — including production date, chamber ID, parameters, and status — are logged in a digital system.
9. Packaging
After aging, the cheese moves to slicing, packaging, and labeling lines.
Each package receives a QR code containing:
Packaging is done in a protective atmosphere or vacuum-sealed to preserve freshness.
Each package receives a QR code containing:
- production date,
- batch number,
- milk origin,
- expiration date.
Packaging is done in a protective atmosphere or vacuum-sealed to preserve freshness.
10. Digital Quality Control
Before leaving the facility, every cheese wheel undergoes:
All data is stored in our ERP system, accessible for internal review and external audit.
- photographic inspection (color, shape),
- weight and density verification,
- pH and moisture testing.
All data is stored in our ERP system, accessible for internal review and external audit.
Safety, Consistency, Technology
Our production is based on a closed technological cycle that fully complies with:
— HACCP standards,
— GOST and EAEU Technical Regulations,
— internal EU food industry standards.
The human factor is eliminated — the cheese never comes into contact with hands.
Every stage is monitored and managed by sensors, algorithms, and digital protocols, ensuring maximum hygiene, consistency, and safety.
— GOST and EAEU Technical Regulations,
— internal EU food industry standards.
The human factor is eliminated — the cheese never comes into contact with hands.
Every stage is monitored and managed by sensors, algorithms, and digital protocols, ensuring maximum hygiene, consistency, and safety.
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