When Suntado set out to build a state‑of‑the‑art dairy processing facility in Burley, Idaho, the company had a clear vision: create a high‑efficiency, high‑capacity plant capable of producing premium low‑acid ESL and aseptic products, all while maintaining strict sanitary design, minimal product loss, and operational agility. To transform that vision into a functioning reality, Suntado turned to Statco‑DSI, a ProMach product brand known across the industry for its leadership in sanitary processing systems and turnkey plant integration.

A new customer testimonial video offers a behind‑the‑scenes look at this collaboration, highlighting both the technology and the engineering discipline required to bring a complex dairy operation online. In a sector where margins are tight and production demands never stop increasing, Suntado’s project offers a case study in how strategic processing design enables long‑term operational performance and, ultimately, stronger packaging and downstream efficiency.

Building a High‑Throughput Processing Backbone

At the heart of Suntado’s facility is a processing infrastructure engineered to move raw milk from tanker to filler as efficiently as possible. With milk sourced from within a 60‑mile radius, the plant is designed around speed, freshness, and minimal hold time. Statco‑DSI supplied the full spectrum of process systems, beginning with blending and standardization operations that lay the foundation for consistent product quality.

From there, the plant incorporates thermal processing capabilities, giving Suntado the flexibility to run ESL or aseptic products with the same high level of food safety assurance. The systems feed into dedicated ESL and aseptic storage, allowing product to transition seamlessly through the operation with minimal shrink and minimal manual intervention.

One of the standout elements highlighted in the video is the facility’s routing architecture. Statco‑DSI engineered automated routing groups designed to interconnect tanks, fillers, and storage systems in a way that supports continuous high‑volume throughput. These routing systems help eliminate manual valve management, reduce production changeover complexity, and ensure the plant maintains consistent product flow during peak demand.

Engineering Through Real‑World Project Challenges

As with any facility of this scale, the journey to a finished plant came with the usual lineup of real‑world challenges: scheduling delays, shifting material availability, weather disruptions, and coordination with multiple contractors. Statco‑DSI’s project management approach, built around responsiveness, on‑site collaboration, and disciplined engineering oversight, played a central role in keeping the project on time, on budget, and in scope.

The video highlights how tightly Suntado and Statco‑DSI worked together during installation. From pipe rack placement to equipment layout, the teams operated hand‑in‑hand to ensure every decision reinforced efficiency, sanitation, and long‑term serviceability. This level of collaboration extended beyond startup. Suntado relied on Statco‑DSI’s 24‑hour support, troubleshooting expertise, and operational guidance as key components in helping the plant optimize production sequencing and equipment performance.

Why It Matters for Packaging Operations

Although this testimonial focuses primarily on processing, the implications for the packaging floor are clear. A well‑engineered processing system:

• Stabilizes product quality before packaging
• Reduces variability that can impact filler efficiency
• Improves uptime by ensuring steady, predictable product flow
• Supports higher throughput without compromising safety or sanitation

For integrated operations, especially those producing multiple product categories across ESL and aseptic portfolios, this alignment between processing and packaging is essential. Suntado’s facility is a compelling example of how upstream precision drives downstream performance.

Watch the Full Story

By pairing advanced thermal systems, automated routing, and high‑touch engineering support, the project shows how modern plants can achieve the efficiency, flexibility, and reliability that the market now demands.

Watch the video to see how Statco‑DSI helped bring Suntado’s next‑generation facility to life.