Case study with video - Boermarke (Dairy Products)

Quote from the customer: "For me, this project is a wonderful example of what is possible when professional business partners work together and contribute their expert knowledge. The SOMIC ReadyPack is an essential link in the production chain for us.”

In 2021, Boermarke Desserts installed a SOMIC ReadyPack as part of a new high-end manufacturing and packaging line. The case packer for a new, promising range was acquired on a lease-purchase basis. We spoke to Reynier Varvik from Boermarke about the challenges, wishes and considerations that led to the decision for the SOMIC ReadyPack and this form of financing.

Boermarke is a company from Enschede in the Twente region on the German-Dutch border that has been producing an extensive range of fresh dairy products such as ice cream, pudding, yoghurt, mousse, porridge, quark and fruit products for almost 40 years. The manufacturer has recently expanded its product range to include plant-based foods: Boermarke now also offers almond-, coconut- and soy-based yogurt, as well as promising plant-based grated and sliced cheeses.

Following the trends

Reynier justifies the expansion of the range with current market trends: “We see that demand is changing and that's why we're doing it. There is a strong trend towards plant-based products on the dairy shelves. We produce distinctive, honest and traditional foods and see a lot of room for our philosophy in this new market segment. The new plant-based products perfectly complement our original milk range and fit in with a conscious and healthy diet.

Our plant-based cheeses are a highlight. The main challenge in developing well-known and widely used plant-based cheese products is the taste and consistency. For us, the taste of a product is and remains the most important aspect and we set the bar high. We have succeeded in producing plant-based cheeses that are indistinguishable from normal cheese in terms of taste, texture, color and smell - an absolutely promising result.

Developed from scratch

In 2021, we put our completely new production line for plant-based cheese into operation. The aim was to produce more than 10 tons per day. Boermarke was the first company with industrial production of the new cheeses on this scale. Until then, nobody had any experience in this segment, and I personally think it was even an advantage that we were not familiar with cheese production up to that point. It is important to know that the product characteristics are completely different from those of normal cheeses. For example, the structure to be processed is completely different. Compared to dairy cheese, the raw mass of plant-based cheese behaves completely differently and the shelf life is also different. We have planned this new production process ourselves from scratch and have gained a lot of experience through this pioneering work.

We have decided not to offer these new products under our own brand name, but to produce them for various retailers. We can therefore proactively market the new products ourselves via our partner companies. The focus is on our grated plant-based cheese and plant-based cheese slices. Through further automation, we want to extend our lead in production, but also in packaging and product presentation. Manual work is expensive and machines do not cause downtime due to illness.

Reliability and small footprint

We set out to find a packaging machine manufacturer that is a leader in the field of cardboard packaging. On the homepage of the trade magazine Verpakkingsmanagement I saw a video of a SOMIC Ready Pack in use at Vepo Cheese. The bags of grated cheese were automatically packed in a wraparound carton. The compact machine and SOMIC's experience with cheese products were the reason to invite the experts from SOMIC to a meeting.

We had two or three meetings and then it was done. To be honest, we looked at several options, but Vepo Cheese's experience report was decisive. It also helps that we have been using a SOMIC insert packer for filled yogurt pots for years. Although the system is very old, it still runs very well. In addition to its reliability, the special technology of the vacuum belt is also remarkable. The decisive factor for me was that the SOMIC ReadyPack is incredibly compact in size and works very precisely. The capacity also meets our requirements 100%. 

Lease purchase fits perfectly into the concept

The lease-purchase option was another reason for us to invest in a SOMIC machine. This payment option fitted in perfectly with our wishes and our situation. Our goal was a high-end line at an affordable price to stay ahead of the market. After the investments in a corona year, it is important that the cash flow fits. We are not a cheese producer, but we have the largest thermoforming and slicing machine available. The SOMIC packaging machine is followed by a palletizer.
Installment plan means that after a down payment for certain parts, the remaining amount is paid off in 36 monthly installments. After these installments, the ReadyPack becomes our full property. It suits our business to be flexible. The monthly outlay is less than the cost of two additional employees for packaging. I am convinced that these investments will pay off. If we still want to repay early for tax reasons, we can do so at any time. It's also good for us that a service contract is included.