Appleby Creamery applies IoT technology to cheese-making

Appleby Creamery, a small-batch cheese producer based in the Lake District is enhancing its traditional production methods and sustainability efforts by adopting Internet of Things (IoT) technology.

Working in partnership with CENSIS, an organisation specialising in digitalisation and enabling technologies, Appleby Creamery has implemented a system to monitor energy consumption and temperature levels at its Eden Valley site. The initiative, delivered through CENSIS’s Milk Round technology accelerator, forms part of the broader Digital Dairy Chain project, a multi-partner venture led by Scotland’s Rural College. The project seeks to transform the dairy processing supply chain across southern and western Scotland, as well as Cumbria, with funding from the UK Research and Innovation’s Strength in Places Fund.

Cheese-making requires precise temperature and humidity control at different stages to ensure product quality and safety. Previously, Appleby Creamery manually checked and recorded conditions in its fridges and ripening rooms during working hours. The newly introduced IoT system now allows for remote monitoring every 15 minutes, 24 hours a day, sending real-time alerts in case of anomalies to prevent product spoilage.

In addition to monitoring environmental conditions, the system tracks energy usage across equipment such as fridges and pasteurisers. Data is displayed on a dashboard developed by CENSIS, enabling the creamery to optimise energy consumption and make more effective use of its on-site renewable energy sources.

The project is being implemented in two phases. Future plans include installing sensors to monitor fuel gas usage and hot and cold water consumption. These upgrades are expected to not only improve cost savings and sustainability but also streamline compliance reporting by automating the tracking of key metrics like temperature and humidity.

Beyond improving efficiency, the system will provide valuable insights for scaling the creamery’s operations and attracting further investment. The sensing technology is affordable, easy to maintain, and can be relocated to monitor different areas of the site as needed.

Founded in 2007 by three former Express Dairies colleagues, Appleby Creamery has grown to employ a team of 12, with plans to expand into Scotland and the south of England. It sources its milk from Crofthead Dairy Farm in Dumfries and Galloway, and its diverse range of cheeses—including brie, blue, and cheddar—are available from retailers such as Booth’s and Tebay Services Farm Shop.

“At first, we weren’t sure if integrating IoT was the right move – we weren’t sure the site was big enough to benefit from this type of technology or what kind of data we would need. But it’s really been a turning point for us. The system has exceeded our expectations in managing and fine-tuning our cheese-making processes, with the whole team involved in seeing how it can drive operational change for our business,” said Maurice Walton, Owner of Appleby Creamery.

“At first, we weren’t sure if integrating IoT was the right move – we weren’t sure the site was big enough to benefit from this type of technology or what kind of data we would need. But it’s really been a turning point for us. The system has exceeded our expectations in managing and fine-tuning our cheese-making processes, with the whole team involved in seeing how it can drive operational change for our business.

Rachael Wakefield, Business Development Manager at CENSIS, added: “This project really showcases how traditional industries like artisan cheese-making can benefit from IoT and other enabling technologies. By retrofitting this system to existing equipment, we’re helping to turn data into actionable insights that enhance decision-making and help the team to explore data driven operational change at their own pace.

“Our aim is to inspire the broader dairy supply chain to embrace digital transformation, especially those at a similar stage as Appleby Creamery or considering lower-cost service options. We’ll be tracking the company’s progress and the impact of the system over time and look forward to sharing the findings. We’re thrilled to support Maurice and the team in demonstrating what’s possible.”

“Digital Dairy Chain is all about people, and how we can help improve and support their businesses. Projects such as this one with Appleby perfectly encapsulates what we are aiming to achieve by bringing cross-industry innovation and technology into the dairy sector to ensure sustainable production and processes. Having CENSIS as a partner has meant that businesses across the region could benefit from this type of technology retrofitting long into the future,” concluded Stuart Martin, Programme Director for the Digital Dairy Chain.

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