Cheese that is released for sale is conveyed to the packaging room, which is on the other side of the production area. Visitors on the observation deck can see four packaging lines where blocks of cheese are broken down into various portions. The main sizes packaged here are 1-pound, 2-pound, and 5-pound loaves and 8-ounce deli and 10-ounce snack packages. In January, Tillamook outsourced some of its packing operations for efficiencies and to speed the time to market. Two co-packers cut, wrap and distribute the cheese.
Tillamook has been modernizing the plant as new technology and equipment are introduced to the industry. And it replaces equipment that is nearing the end of its lifespan. As part of the facility upgrade, Tillamook is building a new cheesemaking clean-in-place room and installing a new CIP system, as well as a new starter room with new equipment.
Besides construction and equipment, Tillamook has invested in new software that gives multiple departments’ accurate, real-time visibility into inventory and financial transactions across the entire company. This allows Tillamook to deliver more consistently and efficiently to its customers.
Safety is a top priority at Tillamook. Each plant has safety committees consisting of employees and supervisors, and supported by managers. They identify and correct hazards in the workplace. The safety department conducts monthly meetings to train and educate employees about the hazards that may occur in a dairy manufacturing facility. A Tillamook representative said the company has “one of the best injury frequencies in the dairy manufacturing industry.”
Tillamook is certified by the SQF certification program, which is under the Global Food Safety Initiative. The plant is SQF Level 2 certified and was awarded a score of “Excellent” after its most recent SQF audit. The SQF audit is annual, but the plant is audited at least three times a year by third-party agencies for customers, whom Tillamook encourages to visit. Both the U.S. Food and Drug Administration and the Oregon Department of Agriculture have jurisdiction over the manufacturing processes
at Tillamook.
The processor conducts its own internal audits designed to continuously inspect its food safety systems in order to ensure high quality. Tillamook audits suppliers regularly and travels the country to evaluate and resolve any issues that may occur. There is a tiered system (from low-risk to high-risk) that is based on allergens and ingredients. A scorecard of sorts evaluates supplier performance from quality to on-time delivery. Tillamook uses HACCP to document all of its systems and it follows this model to ensure safe and quality cheese, ice cream and whey products.
Even though hundreds of visitors a day might crowd an observation deck at Tillamook, the eyes that count belong to the cooperative’s skilled cheesemakers, line operators, laboratory analysts and other professionals who oversee the process of manufacturing award-winning premium cheeses.
