This major upgrade at the plant where Nestlé produces its instant sachets of Nescafé Frothy Coffee, includes the construction of a mixing plant and the installation of two advanced high-tech packing lines, capable of producing up to 60,000 frothy coffee sachets per hour.
The new mixing plant, representing a £17.5 million investment, features the latest equipment and design standards to help make high-quality products more efficiently.
The four-storey facility will reduce heavy lifting by 80% thanks to a new system that handles ingredients in larger bags, cutting down on manual work and improving accuracy.
The plant will also improve operational efficiency and recipe accuracy while supporting the factory’s long-term master plan volumes.
In addition, Nestlé said it is investing £10.7 million in two new packing lines that will replace older lines.
One of the new lines can produce 60,000 sachets per hour using “cutting-edge” technology that ensures smoother and more efficient movement of items. These new lines will be able to use new packaging materials, including MONO PP laminate, allowing for the packaging to be fully recyclable, and supporting Nestlé’s sustainability goals.
Richard Watson, CEO of Nestlé UK & Ireland, said: “We are very proud of our British manufacturing and this investment reflects the great work being done by our teams to position the UK as a market with significant manufacturing expertise and capability.
“The Dalston investment is a prime example of how we’re investing in the future of the British food and drink industry - modernising our operations and supporting local jobs, driving growth opportunities and being more sustainable.”
Ian Pipes, Nestlé Dalston factory manager, said: “We are delighted to have secured this investment which marks a significant step forward for our Dalston site. By upgrading our facilities with the latest technology, we’re not only improving product quality, but also creating a more sustainable and supportive environment for our teams.”
The upgrades at Dalston will help deliver even better products to consumers while reducing environmental impact and improving efficiency on site.
Nestlé Dalston has been producing Nescafé Frothy Coffee products since 1962.
Recognised as a Centre of Excellence for Frothy Coffee for Nestlé globally, the factory manufactures popular products, such as Nescafé Cappuccino and Latte, Coffee Mate, as well as Starbucks’ range of Latte products.
The factory was originally built in Cumbria due to its proximity to dairy farms which provide the sustainable fresh milk needed to produce 25 million Nescafé Cappuccino and Frothy Coffee sachets every week.
Nestlé said it has worked with First Milk since 2010 to promote responsible farming, enhance animal welfare, and protect Cumbria’s natural landscape, ensuring that the fresh milk used in Frothy Coffee products is not only high-quality but also sustainably sourced.
