The Solution

Birch & Waite partnered with RMR Process to design and deliver a state-of-the-art production facility in Revesby, NSW. The RMR Process team provided:

Innovative Facility Design: Created plans for a $13.5 million factory featuring the Southern Hemisphere's first commercial-sized Shaking Retort technology

Specialized Process Engineering: Implemented advanced thermal cooking processes specifically designed for high pH sauces containing fresh ingredients

Project Management Excellence: Delivered comprehensive oversight from concept through to operational handover

Cost-Effective Implementation: Completed the project at an affordable price point while meeting all technical requirements

The centerpiece of the solution was the innovative Shaking Retort technology, which revolutionized Birch & Waite's production capabilities through improved thermal processing.

Case Study:

Birch & Waite

The Challenge

Birch & Waite, a family-owned Australian food manufacturer, faced significant challenges in their growth trajectory:

  • Product Innovation Limitations: Their existing facility lacked the advanced technology needed to produce premium health-focused products with superior taste and nutritional value

  • Market Expansion Barriers: The company identified growth opportunities in the aged care health sector but required specialized production capabilities

  • Quality Constraints: Traditional processing methods limited their ability to maintain fresh flavors and nutritional content in products with longer shelf life

  • Production Capacity: The company needed additional manufacturing capacity to support their projected business growth

These challenges were preventing Birch & Waite from fully capitalizing on market opportunities and expanding their product range beyond their existing capabilities.

The Results

The partnership with RMR Process delivered transformative outcomes for Birch & Waite:

  • Business Growth: Positioned to drive over $20 million in growth for the business

  • Product Quality Enhancement: Achieved higher vitamin retention, lower salt use, better appearance, and superior taste while maintaining longer shelf life

  • Market Expansion: Successfully entered the aged care health sector with specialized thickened liquid health products for dysphagia patients

  • Employment Creation: Generated up to 45 new full-time jobs at the Revesby facility

  • Premium Product Development: Enabled production of chef-quality products in convenient sachets for both consumer and professional markets

Key Takeaway

Birch & Waite's experience demonstrates how strategic investment in innovative food processing technology, guided by expert design and project management, can transform manufacturing capabilities and unlock significant business growth opportunities.

"Peter Taitoko and his team from RMR have been very innovative in their design and project management to deliver this project in a timely manner and affordable price." - Willi Schultheiss, Director, Birch & Waite