California Dairies Looks to the Future with High-Tech Valley Natural Beverages Plant

Ultra-high temperature processing: designed for precision and product diversity

The Bakersfield plant’s ultra-high temperature (UHT) system is the centerpiece of its liquid processing operation, allowing CDI to produce a wide range of high-value products—from shelf-stable creams to extended-shelf-life milks—within a single, tightly controlled framework.

Configured with direct steam infusion technology and a closed aseptic loop, the UHT system enables rapid thermal treatment while maintaining the product’s sensory and nutritional quality. Milk is heated to ultra-high temperatures for only a few seconds and then cooled immediately under sterile conditions, preserving the fresh dairy flavor that customers expect.

What makes the Bakersfield setup distinct is its scalable design and recipe-driven flexibility. Operators can switch between product types with minimal manual intervention, as temperature profiles, flow rates, and hold times are all preprogrammed and automatically executed through the plant’s control interface. The same base system can produce fluid milk one shift and whipping cream or nutritional formulations the next.

The integration of UHT with aseptic and ESL filling lines also streamlines production and minimizes exposure risk. Product flows directly from the sterilizer to filling, maintaining an aseptic environment throughout the process. This configuration supports both domestic refrigerated distribution and export of shelf-stable products—key to CDI’s long-term strategy of diversifying markets for its member farms.

To support future growth, the plant’s utility corridors and floor space were laid out to accommodate additional UHT trains as capacity needs rise. “We built this system with long-term flexibility in mind,” says Hancock. “We can expand throughput, add parallel heat exchangers, or tailor parameters for new formulations without redesigning the plant.”

All the systems at the Bakersfield plant are fed by a separator from GEA, a roughly 6-ft-tall and 6-ft in diameter conically shaped machine, that starts the entire process as raw product is received. Because CDI wanted the plant to ultimately be completely self-sufficient, the separator essentially acts as the heart of the facility.

“The GEA separator allows us to effectively get the cream and skim milk, the two components needed for most products that we produce,” says Ponce, adding that while there are other options to get those components, those options wouldn’t allow the facility to do everything internally.

Sitting near the separator is another high-tech piece of equipment that sets the Valley Natural Beverages facility apart: the JCS UltraBlend.

“UltraBlend is for a batch, such as a 1% or 2% mix, where we have to combine skim and raw milk to get a desired percentage,” says Ponce. “This will do all the math for you.”

And instead of sending it to the batch tanks, the UltraBlend can send the mixture directly to the UHT. If additional vitamins are needed for the product, that dosing occurs at the UHT.

“This is a quick way of being able to batch,” Ponce says. “Batches can be run directly from this all the way to the UHT.”

The UHT system’s combination of automation, sanitary design, and scalability positions VNB Bakersfield as one of the most advanced liquid dairy processing facilities in the western U.S.

Automation beyond the processing floor

Automation extends well beyond production. The Bakersfield plant’s automated storage and retrieval system (ASRS), supplied by Interlake Mecalux, provides a total of 8,400 pallet positions in a segregated warehouse—one side refrigerated for ESL products and the other ambient for aseptic.

“It’s a lights-out warehouse,” says Ponce. “Operators load materials into the system, and from there, everything is automated through palletizing, stretch wrapping, and storage. It’s a smooth flow that reduces manual handling and improves safety.”

The ASRS is integrated with the plant’s production scheduling and order management software, enabling automated load sequencing and trailer staging. A lockout-tagout system prevents personnel from entering the warehouse while cranes are operating. “Safety was built into every layer,” Ponce says. “You can’t just walk into the ASRS—it will automatically shut down. That’s the level of control we wanted.”

The ASRS is integrated with the plant’s production scheduling and order management software, enabling automated load sequencing and trailer staging.Danny Klorman / California Dairies, Inc.

Water stewardship and wastewater innovation

Sustainability was a non-negotiable part of the Bakersfield design, particularly in water management. The facility features a dedicated anaerobic digester and advanced membrane bioreactor (AnMBR) for wastewater pre-treatment—systems that go beyond the standard equalization tanks used in most food plants.

“We’re really trying to set a new standard for effluent management,” Hancock says. “Most facilities just manage pH. We’re digesting and capturing biogas, reducing organic load, and planning to repurpose treated water.”

One of the site’s biggest advantages is its location adjacent to a municipal wastewater treatment plant. A 14-million-gallon-per-day pipeline runs beneath CDI’s property, carrying treated effluent.

“Water stewardship is anchored by a dedicated, onsite wastewater treatment facility, ensuring we are a good partner to the community,” Hancock says.

On the inbound side, all process water passes through reverse osmosis (RO) treatment, provided by Polaris with integration from JCS. “California has strict limits on salts and total dissolved solids,” Hancock says. “Using RO helps us meet those standards while reducing chemical use in cleaning.”

Powering the plant—and then some

Energy management is another area where Bakersfield stands apart. The site could eventually run completely off-grid through a combination of linear generators, solar, and combined heat and power (CHP) systems.

Ten linear generators, currently being installed, will produce around 2.3 megawatts. Unlike conventional generators, the linear design uses no combustion and can run on multiple fuels—including natural gas, biogas, ammonia, and hydrogen. “They’re fuel-agnostic and ultra-efficient,” Hancock says. “We can transition fuels over time without replacing equipment.”

Complementing the generators are two 5-megawatt CHP turbines, which will provide both electricity and process steam. Solar panels installed on the south end of the property will supply additional renewable power, bringing total generating capacity to around 12 megawatts.

“California power rates are among the highest in the country,” Hancock said. “We’re paying 30 to 35 cents per kWh from PG&E. We believe we can produce our own for less than 20 cents. The goal is complete self-sufficiency.”

Refrigeration and safety systems

The Bakersfield plant uses ammonia refrigeration—a deliberate choice for both performance and sustainability. “Ammonia is actually the most energy-efficient and environmentally friendly refrigerant available,” Hancock says. “It provides better cooling with lower power use than synthetic alternatives.”

For safety, the ammonia system is fully isolated to a single engine room. Throughout the rest of the facility, a glycol loop provides chilled water for process and storage areas. “There’s no ammonia in any occupied area,” Hancock emphasizes. “We’ve got sensors and shutoffs everywhere. Worker safety is the top priority.”

Employee-focused design

While automation plays a central role, CDI also designed the plant to support the people who keep it running. Drivers have a dedicated lounge area to rest between milk deliveries, and all production spaces are climate controlled.

“We wanted to make this a comfortable, safe environment,” Hancock says. “Our employees are working in conditioned spaces year-round, and that’s rare in processing.”

The maintenance department is equipped with modern tools, including an automated parts lift system that retrieves components from vertical storage trays at the touch of a button. “It saves space and time,” Hancock says. “It’s the kind of efficiency that makes day-to-day operations smoother.”

Sustainability was a non-negotiable part of the Bakersfield design, particularly in water management.Danny Klorman / California Dairies, Inc.

Global reach, local mission

The Bakersfield plant’s location also enhances CDI’s global strategy. The cooperative has already begun exporting products to Mexico, Cambodia, and South Korea, focusing on higher-fat products like cream and whipping cream.

“There’s growing recognition of dairy’s nutritional and functional values. Our new capabilities put us in a strong position to serve that demand,” says Hancock.

Ultimately, every decision behind the Bakersfield plant ties back to the farmers who own CDI. “Everything we do is about getting our member-owners the best return on their milk,” Hancock says. “We’re owned by dairy families, and this facility helps secure their future.”