Double de-brining increases flexibility at De Graafstroom.

Since 1908, De Graafstroom has been producing cheese in Bleskensgraaf. Where milk used to be delivered by boat, today insulated trucks drive in and out of the facility. With around 100 employees, the company produces various types of cheese day and night, six days a week. De Graafstroom reached out to DERO GROEP to explore how they could further optimize their production process.

“We already had considerable production capacity, but we noticed we were hitting a limit in our brining department,” says Marjorie Sonepouse, head of production at De Graafstroom. With an eye on further growth, the company wanted to make an efficiency leap, without disrupting daily operations.

Two cheese types, one line

The factory produces both natural rind cheese and foil-ripened cheese, both of which require a brining stage after molding. “We only had a single de-brining line. If something went wrong there, the entire process came to a halt,” Marjorie explains. “That became a bottleneck over time.” Given the growing labor shortages in the sector, automation became a logical step for De Graafstroom.

Double de-brining and more efficient cleaning

Together with DERO GROEP, the decision was made to install a second de-brining line, allowing natural and foil cheeses to go through the brine simultaneously. “It really saves a lot of hassle when you need to switch quickly,” Marjorie says. Hygiene was also improved: a ‘floor-free’ support structure prevents the need for numerous legs touching the ground, which would otherwise require intensive cleaning. In addition, part of the cleaning process was automated, making cleaning faster and easier. The conveyor systems were designed in accordance with EHEDG guidelines and meet the highest hygiene standards for food processing.

“We installed an overarching base frame in the available space and suspended as many conveyor lines as possible from it,” explains Rachid, lead engineer at DERO GROEP. “One side is mounted to the wall, while the other rests on a minimal number of floor supports. This allowed us to fit 90 meters of conveyor lines using only 15 support legs. De Graafstroom also contributed actively to this process and took a pragmatic approach.”

De Graafstroom's de-brining line in action.

Running production daily

A major question during the design phase was how to keep production running during the renovation. “We can't just shut down for three days,” Marjorie emphasizes. “So together with DERO GROEP, we created a plan to execute everything in smaller phases—removing old parts and installing new ones during short timeframes.” This approach kept the cheese plant operational, and each step was immediately tested upon completion.

More flexibility, less downtime

The new brining setup allows two cheese types to be de-brined simultaneously. “If there's a malfunction on one line, the other can keep running,” Marjorie explains. This minimizes downtime in the cheese plant. Cleaning rounds are also more efficient, thanks to both the automated cleaning process and the hygienic design.

Ready for the future

With the bottlenecks in the brining department resolved, De Graafstroom is ready for future growth. “We're always looking at ways to improve. And when we're ready to automate again, we know DERO GROEP has the experience,” says Marjorie.

Happy with the partnership

According to Marjorie, the decision to partner with DERO GROEP came down to their industry knowledge and collaborative approach. “I consider DERO GROEP to be a reliable partner,” she says. “They have extensive experience in this sector, which makes a big difference.”

Want to boost your capacity or streamline your production process through advanced automation, just like De Graafstroom? Contact DERO GROEP and discover how customized automation can strengthen your cheese production.