Operations

Tauranga

The Tauranga operation consists of two main parts:

Factory 1 is a dedicated meat production facility where the mussels are steamed open under pressure and the meat is then extracted for either the 'Individually Quick Frozen' meat market or for further processing into a combination of four marinade flavours - Chilli, Wood Smoke, Garlic and Natural. The plant produces on average approximately 6000-8000 375g pottles daily for local and export markets.

Factory 2, our new state of the art processing unit, utilizes the worlds first robotic mussel opening equipment with laser and camera technology.

Size graded  fresh live whole mussels are 'heat shocked popped' using specially developed counter current - water shower processing equipment.

The pasteurised (or sterile) product then enters the Automated Mussel Openers (AMO) hall, which was developed in New Zealand and technology patents are held by NIML partner Sanford Ltd. This cutting edge process enables a better controlled and higher yield factor than opening mussels by traditional hand shucking. 56 Robotic manipulators ensure clean efficient processing of the bulk of Factory 2’s production. Simply, the AMO cuts the adductor mussel on one side of the mussel leaving a half shell with meat attached, which provides a table ready presentation of one of New Zealand’s iconic sea foods, Greenshelltm Mussels.

Following visual quality inspection the 'Half Shell Mussel' is Individually Quick Frozen in 15minutes down to a temperature of -18c. The continuous spiral freezing system utilizes an integral re-freezer that encapsulates the final glaze applied to the product.

Multi-head weighing technology ensures fast and accurate weighing of the product into its retail / wholesale sized units for shipment. The final product is packaged in a vertical form-fill and sealed bag placed into an inner and outer carton, protecting the contents during export many to destinations throughout the world.

Processing Statistics  
Factories On Site 2
Factory 1 capacity green weight 3,000 Kg per hour
Factory 2 Capacity green weight 6,000 Kg per hour
Robotic Openers (AMO’s) 56 Lanes
Hand Openers 24
Freezing Capacity on site 2,205 kW
Water consumption 800m3 / day
Staff 270 including seasonal staff
Record Half shell pieces opened Factory 2 1,750,000 / day
Ultimate capacity per annum 30,000 metric tonnes