Case Study: Boosting Efficiency with DCN Kettle Systems
February 13, 2024
Author: Annabel Norris, Marketing Manager
Beerenberg, a family-owned business rooted in South Australia since 1839, has evolved from a humble strawberry farm to a global producer of 100+ gourmet products, including jams, honey, chutneys, relishes, mustards, dressings and sauces. Their journey from a small kitchen on their farm to international markets posed the challenge of scaling-up production while maintaining product quality and diversity.
The Challenge
In 2016, Beerenberg embarked on a new chapter of expansion by constructing a state-of-the-art factory extension. The challenge was to invest in food processing equipment that could elevate product quality, accommodate diverse recipes, and handle larger volumes. Beerenberg’s product range, which spans from many different variants demanded flexibility in their production process.
The Solution
To address Beerenberg’s production needs, DC Norris introduced two 1000-litre Steam Jacketed Kettles with customised features:
DCN Jet Cook™: Improved cooking times, product quality, and energy efficiency.
Split Steam Jacket: Enabled cooking of both large and small batches without burn-on.
Vapour Reduction: Reduced processing times, improved efficiency and consistency of jams and marmalades such as their Beetroot and Caramelised Onion relish.
Tracked and Guarded Tote Bin Hoists: Reduced manual handling and enhanced operator safety.
Internal and External Homogenisers: Allowed for fine purees and re-circulation options.
Wash In Place (Mild CIP): Facilitated product rinsing and detergent washing for sanitisation. Wash in Place: The kettles have streamlined the cleaning process, ensuring hygiene and reducing downtime.
Full Recipe Manager Software: Enhanced control over the cooking process, including timings, batch temperatures, and weights.
Training and Support
DC Norris provided comprehensive training to Beerenberg’s team, ensuring they could optimise the use of the kettle systems. On-going support and maintenance continue to be offered, ensuring uninterrupted production.
Results and Benefits
The DCN Kettle Systems at Beerenberg have transformed their production processes, the initial two
kettles were projected to serve Beerenberg for a decade. However, due to the company’s success and rapid expansion, they recently added two more 1000-litre kettles. The results have been outstanding:
Top-Quality Products: Beerenberg produces exceptional products that have gained global popularity.
Efficiency: Large volumes are produced in reduced timeframes, allowing for a faster turnaround between batches.
“The DCN Kettle Systems have been a game-changer for Beerenberg. Our production has reached new heights, and the quality of our products continues to impress our customers.”
Conclusion
Beerenberg’s success story is one of continuous growth and innovation. They have expanded their operations to include a large kitchen production area and a farm café, where visitors can enjoy fresh food, tastings, and cooking demonstrations. DC Norris takes pride in being part of Beerenberg’s journey and looks forward to a continued partnership with the team at FPE as they write the next chapters of their success story.