EFESO Management Consultants help dairy facility with automation and efficiency
A prominent dairy and juice producer has successfully launched a large-scale production facility in Saudi Arabia’s Sudair Industrial City following a strategic partnership with consulting firm EFESO Management Consultants.
The project, a “greenfield” investment built from the ground up, represents a significant expansion for the manufacturer as it seeks to meet growing regional demand for fresh beverages. By integrating advanced planning and automated technology, the company has established a site capable of producing 170 million liters annually.
Optimization and automation
The project faced several complex hurdles from the beginning. The facility needed to manage over 50 different types of products while maintaining strict food safety and hygiene standards. These regulations require the physical separation of people, raw materials, and waste products.
In order to solve these challenges, EFESO Management Consultants helped design a layout that optimizes the flow of goods across a 30,000 square meter footprint. This ‘I-structure’ design ensures that materials move in a lean, logical path, which also leaves room for the factory to expand in the future.
Automation sits at the heart of the new operations. The consultants oversaw the implementation of nine high-speed filling lines and a fully automated transport system. Goods move from the filling stations to delivery trucks using self-driving vehicles and high-bay storage systems.
This technological shift has allowed the producer to reduce the physical space required for storage by nearly 50% while simultaneously decreasing the number of staff required for manual logistics by 35%.
More efficient and sustainable
The collaboration also focused on speed and financial efficiency. By using integrated planning techniques, the team shortened the time required to bring the facility from the concept stage to active operation by 25%. This approach allowed the manufacturer to bypass common delays and design errors that often plague large-scale industrial builds. The result is a highly efficient, scalable factory that balances high performance with disciplined investment costs.
Beyond the immediate production gains, the facility is designed for long-term sustainability and operational excellence. The new systems provide a 20% increase in space efficiency compared to traditional dairy plants.
By aligning the processing technology for both juice and dairy under one cohesive plan, the producer is now positioned to maintain a competitive edge in the Middle Eastern market while upholding the highest international quality standards.
“This integrated, cross-disciplinary methodology enabled the client to move from concept to operation with a fully aligned factory system covering technology, people flows, material flows, and building design in one coherent solution,” said EFESO Management Consultants in a press release.
