Simplot Ulverstone plant upgrade: Making room for chipping champs

TASMANIA’S North-West is famous for producing great potatoes and a major processing plant is ready for an upgrade and expansion. KAROLIN MACGREGOR reports.

GROWING: Production manager Tony Griffiths, left, process area manager Jason Spinks and process area operator Michael Tummon at the Simplot factory at Ulverstone. Picture: CHRIS KIDD

Just like the farming area around it, the Simplot factory site has changed a lot since it was first established at Ulverstone in the state’s North-West in 1942.

Back then the original factory was used to processed canned rabbit and later fish until JR Simplot company founder Jack Simplot recognised the state's potential for producing vegetables and potatoes.

After lobbying the then state government, the Simplot factory was converted for potato production.

Nowadays the Ulverstone facility plays a crucial part in Simplot Australia's business and a $51.3 million expansion at the factory is scheduled to start soon.

Part of that expansion is being funded with a $12 million grant from the Federal Government's Regional Growth Fund.

Factory manager Nigel Cowen in the potato storage shed. Picture: CHRIS KIDD

Ulverstone plant manager Nigel Cowen says one its biggest strengths is the facility's 320-strong workforce.

“That's probably our biggest competitive advantage, the people we have working here,” he said.

“Anyone can have a factory with all the equipment, but it's the people who make the biggest difference.”

The Simplot employees have been with the company on average about 16 years, but some have worked there a lot longer.

Lyn Murphy is due to retire in two weeks after working at the factory for 36 years.

When she first started there all the chips were bagged by hand.

More spuds arrive. Picture: CHRIS KIDD

After working her way up to be one of the factory's first two women process operators, she now works in the quality-assurance area.

Despite her looming retirement, Ms Murphy said her plan was to come back as a casual employee once the compulsory three-month time period is up.

“There aren't many places that allow you to do that, but this is a really good place to work,” she said.

“They pay well and they look after everyone and the conditions are good.”

Tony Griffiths is another long-term employee with 37 years at Simplot.

“The opportunities I've had through this company have been amazing,” he said.

“I'll be here until I retire.”

Grading room operator Lyn Murphy. Picture: CHRIS KIDD

Apprentice fitter and turner Zara Freeman. Picture: CHRIS KIDD

Some families also have multiple generations who have worked at the factory.

Mr Cowen said the company valued the knowledge and experience of its older employees.

“One of the big things we want is for the employees with all those years of experience to be able to pass on that knowledge to be able to pass some of that on to the younger people who may just be starting out here,” Mr Cowen said.

One of the company's newest employees is apprentice fitter and turner Zara Freeman, who has been working there for two months.

Originally from a farm in New Zealand, Miss Freeman said she was thoroughly enjoying the challenges of the job so far.

“At first I thought it was mechanical apprenticeship … when I got here I realised it was something completely different,” she said.

“It’s worked out really well though because I’m enjoying this even more.”

Processing at the Simplot plant at Ulverstone. Picture: CHRIS KIDD

This year the factory will process about 310,000 tonnes of potatoes, which is a record crop.

The potatoes are supplied by about 165 growers and harvesting is now in full swing.

Mr Cowen said growing demand for the company's products, particularly its specialty battered lines, was the main reason to expand. He said the new facility, to be built next to the existing factory, would allow Simplot to increase production and product innovation.

There is storage capacity for 81,000 tonnes of potatoes on site and another 81,000 tonnes off site.

Some potatoes are processed straight after harvesting.

To keep up with supply, the factory runs 24 hours a day seven days a week.

Investment in an on-site power generation plant has been another major development. Gas is used throughout the factory and the power plant generates enough to run the whole factory and has some excess to supply back into the power grid.

Minimising waste throughout the processing lines is a big focus.

“It takes a lot of time, effort and money to grow the potatoes, so we try to make sure we use as much of them as possible,” Mr Cowen said.

High-pressure steam is used to blast off the potato skins before the spuds are put through one of the two chip lines.

Once cut the chips are graded for size and any chips with blemishes are separated and trimmed to remove the defects.

Small pieces not big enough for the chip products are used to make hash browns or dehydrated. The potato skins are either used for stock feed or composted and used on farms.

Dirt washed off as the potatoes are moved around the factory is collected in settling ponds and regularly dug out to be spread back on to growers' farms.

Mr Cowen said the company spent a significant amount of money each year maintaining and upgrading its processing lines.

The latest investment plan will allow the company to remain competitive.

“That's what the investment is all about, we need to keep improving and innovating because if you're standing still you're actually going backwards,” Mr Cowen said.