LGPM partners with Maltra Foods

LGPM talks about its long-term partnership with Maltra Foods that has supported the growth of both companies over the past two decades and beyond.

LGPM was originally engaged by Maltra Foods over two decades ago in 2002, to design, manufacture, supply, and install a new mixing system to replace its existing manual production methods.

The first installation introduced a 1.0 m³ ribbon mixer with manual hand additions, discharging directly into a packing machine.

From the beginning, the project was approached with clear objectives:

Deliver a system within budget constraints
Ensure the design was operator-friendly and safe
Achieve output levels beyond expectations
Provide low maintenance requirements

Most importantly, Maltra Foods wanted a solution that formed part of a broader strategic plan.

This meant the solution had to have a future-proof design that was capable of semi-automation, expansion, and integration into a larger facility.

Since installation, the system has consistently delivered strong, reliable results, strengthening the partnership between LGPM and Maltra Foods. Through ongoing collaboration and strategic investments, the plant transformed from a single ribbon mixer into a fully integrated batching and blending facility.

By 2010, the strategic plan had come to life with additional mixing lines, each automatically batched and weighed via gain-in-weight systems.

Raw materials were introduced through the addition of two bulk sugar silos, bulk bag dischargers for macro ingredients, and dedicated hand-dumping stations for minor ingredients.

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Bulk materials were conveyed via a vacuum transfer system into weigh hoppers, ensuring precise dosing and dust-free handling.

Finished batches are stored in intermediate bulk containers (IBCs), which are transferred into storage and then into the packing hall.

The packing hall included packing lines supported by the IBC discharge stations, providing the capacity and flexibility to meet diverse customer requirements across a wide range of package formats, from single-serve sachets to larger-size bags and containers.

Relocation and purpose-built facility

As Maltra Foods expanded, by late 2010, the business had outgrown its Moorabbin plant and planned a move to a new, custom-designed premises in Clayton with a vision to be able to work with a wider range of small and medium enterprises and multi-nationals.

LGPM collaborated closely with Maltra Foods during the design phase, ensuring the layout supported streamlined material movement, clear segregation of processes, and rapid cleaning routines. The relocation was carried out during the Christmas 2010 shutdown, ensuring minimal disruption to operations.

The new plant was designed with efficiency, hygiene, and optimal product flow in mind.

The relocation included the design and installation of a new structural framework for batching and blending. While structural steelwork is often secondary to process equipment, in this case, it was integral to the plant’s hygiene and safety standards.

LGPM engineered a portal-frame design integrated into the building envelope, with clear-span mezzanines that eliminated the need for internal bracing or columns within production rooms. This clean design reduced surfaces where dust could accumulate, accelerated daily cleaning, and meant the risk of cross-contamination was minimised.

Conveying lines and services were routed externally or within the steelwork itself, with only localised penetrations at termination points. The result was a plant designed not only for production efficiency but also for long-term compliance with food safety standards.

During the design, additional space was allocated for future automated macro/micro batching, further raw material processing, and a blending line.

The facility features dedicated blending rooms with independent systems to ensure product segregation, flexibility during changeovers, and improved allergen management.

Advanced automation and integration deliver consistency, traceability, and streamlined operation.

In 2025, Maltra Foods is expanding once again and has commissioned LGPM to design and build a brand-new facility in Pakenham, Victoria.

This new project is not just about increasing production capacity—it represents the culmination of more than two decades of collaboration, trust, and shared expertise between the two companies.

Through years of working together, LGPM has gained an in-depth understanding of Maltra Foods’ processes, operational challenges, and growth ambitions. Every decision in the Pakenham facility’s design – from production line layout to automation and material handling systems – is informed by this extensive knowledge.

The result will be a facility optimised for efficiency, scalability, and flexibility, capable of handling future product diversification with the same high standards of quality, hygiene, and food safety that have defined the partnership since 2002. A key feature of the facility will be its built-in capacity for future growth. This forward-planning approach reflects both Maltra Foods’ vision and LGPM’s commitment to delivering effective and efficient solutions.

“The new Pakenham facility embodies the trust and collaboration we’ve built over more than 20 years,” LGPM said in a statement.

“Every aspect reflects the lessons learned and innovations developed throughout our partnership with Maltra Foods.”

Standards and certifications

Maltra Foods has established itself as a trusted manufacturer by maintaining robust quality and safety systems throughout its all of its manufacturing operations.

The facility is designed and operated in compliance with internationally recognised standards, including: