Ornua: Kerrygold Park

Background

Ornua (formerly the Irish Dairy Board) is an agri-food commercial co-operative that markets and sells dairy products on behalf of its members, Ireland’s dairy processors and, in turn, the Irish dairy farmer. It’s Ireland’s largest exporter of Irish dairy products and proud owner of the iconic Kerrygold brand.

Ornua has sales and marketing teams working in-market across all four corners of the globe. Headquartered in Dublin, it exports to over 110 countries with annualised sales of circa 2.5 billion. In September 2016 Ornua opened Kerrygold Park, a 38 million state-of-the-art butter production and packing facility in Mitchelstown, Co. Cork. The 65,000 sq. ft. facility has a production capacity of c. 50,000 tonnes a year with 63 product lines expected to operate from the facility in 2017.

As part of this investment, Ornua decided to improve and develop the packaging for their Kerrygold spreads range. Quinn Packaging having been a trusted supplier to Ornua for over two decades was the preferred partner for this project.

The Brief

The brief came in early 2016. Ornua asked us to develop a new injection moulded (IML) dairy spread container for their 500g Kerrygold product. The new product – an evolution of the existing pack – required an improved Lid design making it suitable for foil-sealed tubs. The Tub also required design improvements to optimise sealing and enhance packing line performance.

A stringent and challenging timetable was agreed which ensured we designed the right product whilst still delivering on schedule.

The Process

The project required a design change to the existing pack format which incorporated a number of key product features demanded by the customer, whilst maintaining its existing functionality.

The approach to the project by the Quinn Packaging technical team was one of early involvement of all key stakeholders including the customer, toolmaker and label supplier. This principle ensured that all parties were aligned to ensure that the project timelines were successfully adhered to.

Timeline

February 2016 – Product Drawings, Design Approval

March 2016 – Production stock build at Quinn Packaging

April 2016 – Moulds shipped to Muller, Switzerland for modification

June 2016 – Mould testing and product approval at Muller

July 2016 – Full Production commences at Quinn Packaging

August 2016 – Supply commences to Ornua

The Outcome

“Quinn Packaging impressed us with their professionalism and expertise. They really took ownership of the project, and walked us through every stage of the development process. That’s the kind of support we needed, and it was reassuring to have such experienced personnel leading the development.

The Quinn Packaging technical team understood the importance of meeting our deadline, and despite the many challenges which the project presented we were confident at all times that these would be achieved.

The fact is they made it simple for us. They knew what they were doing, and how to go about it in the most efficient way. That’s the kind of partnership we needed on this project.”

Richard Cumiskey, Packaging Innovations Manager, Ornua