Production and Shipment
The Rise of Our Himalayan Dairy Plant:
A Three-Phased Vision Manifested
Phase 1
Dog Chew/ Chhurpi Ghee & Nauni
Phase 2
Yogurt Mohi & Pasteurized Milk
Phase 3
Biogas
1. The Foundation: Building in the Himalayan Embrace
At the foothills of the majestic Himalayas, we are in the process of establishing our plant of approximately 40,000 sq ft. Half of this space (20,000 sq ft) is dedicated to an indoor facility focusing on processing and production pipeline including pasteurization, cutting, drying, dispatch preparation as well as administrative operations. The remaining 20,000 sq ft outside accommodates vital installations like boilers, generators, compressors, and firewood storage, some of which are housed in auxiliary structures. Our ambitious vision targets early 2024 for the plant’s inauguration, with a remarkable initial processing capability of 80,000 liters of milk each day.
2. Phase One: Tradition Meets Modernity
Products of Distinction
Dog Chew/Chhurpi
Destined for US shores, this premium product reflects our commitment to quality.
Ghee & Nauni (Nepali Butter)
Rich, wholesome, and healing, these treasures cater to local markets and major cities across Nepal.
3. Safety, Purity, and Hygiene: The Heartbeat of our Operations
To us, safety is paramount. While locals might have a history with raw milk, our milk products, including milk pouches, yogurt (introduced in Phase Two), and the famed mohi, all emerge from strictly pasteurized processes. This ensures every drop consumed is free from harmful pathogens, offering a safer, more nutritious alternative.
4. Beyond Dairy: Our Eco-Conscious Endeavors
Our whey water, a byproduct of dog chew processing, becomes a nutritious feast when combined with grains, serving as an irresistible, wholesome meal for boars.
5. Phase Two: Expanding Horizons & Deepening Roots
Our horizon expands as we plan to house 500 cows, thriving on lush grasslands within a 5-mile radius of our plant. This phase introduces:
Yogurt
Presented in quaint clay pots, a nod to tradition.
Mohi & Pasteurized Milk
Securely encased in robust plastic pouches. Mohi, especially, embodies the soul of Nepal, offering cooling relief during sweltering days. Its bottled version aims to rival mainstream soft drinks, presenting a healthier, culturally-rich alternative to products like Coke and Pepsi.
6. Phase Three: The Grand Vision of Self-Sufficiency
We dream big. Envisioning an expansion to 10,000 cows, we plan to be self-sufficient in our milk needs. At the heart of this phase lies our innovative biogas pipeline, a dream project of our esteemed founder, Mr. Narendra, intending to fuel local communities.
Plant in Germany
Our Journey in Germany: Kukuje & Dauer Kauer
Quality at the Source
Our commitment to quality starts at the source. In Germany, our milk is sourced exclusively from cows that roam freely in green pastures. This natural, grass-fed diet ensures a pure and premium base for our products.
Two Plants, One Vision
With two advanced manufacturing plants in Germany, we process an impressive 40 thousand liters of milk every day. This capacity enables us to produce and supply dog chews to ten major European retailers and five key wholesalers and retailers in the US.
Our Brands: Recognition and Reach
Throughout Europe, we are known and loved as “Kukuje” and “Dauer Kauer.” Our products’ reputation for quality has allowed them to be rebranded and sold under more than 100 different brands in the US, demonstrating our wide reach and versatility in the market.
Scaling Up with Ambition
Guided by Narendra’s forward-thinking vision, we’re always looking ahead. Although we currently produce about 50 tons of dog chew every month, our plants have the potential to handle much more. With our German facilities capable of processing up to 300,000 liters of milk daily, we have the capacity to produce 350 tons per month solely at these locations to meet rising market demand. Additionally, we’ve invested in the latest machinery, positioning us at the forefront of technological advancements in our industry.
Future Plans: Growth and Consolidation
We’re not stopping here. Plans are underway to consolidate our operations. We’ve acquired a vast 10,000 sq m plot where we aim to bring both our plants under one roof. This new facility will be custom-built by us, equipped with all the modern technologies and machinery, ensuring that we continue to deliver the best to our customers.
In Germany, our approach has always been straightforward: deliver the best quality, remain consistent, and always be ready for the future.
How is dog chew made?
From farm to Pup: Crafting the Perfect Dog Chew
Milk's Majestic Arrival
In our state-of-the-art German plant, we lovingly source fresh cow milk from local farmers. Their cows roam freely, feasting on lush, green grass. This ensures that the journey of creating the perfect chew starts with the best ingredients.
The Art of Pasteurization
Using stringent European standards, we pasteurize the milk to eliminate any bacteria. During this process, we meticulously separate most of the rich cream from the milk, ensuring the perfect base for our chews.
The Birth of Cheese
Once pasteurized, the milk is gently heated and coagulated using natural lemon juice. This magical chemistry gives birth to cheese and whey water.
The Great Press
Our cheese is then carefully wrapped in traditional jute cloth and pressed. Imagine the weight of two adult African elephants pressing down on it! After an extended period of rigorous pressure, we gently remove the jute cloth and unveil the beautifully pressed cheese.
Shaping the Future Chew
The cheese is allowed a pre-drying phase to reach its optimal consistency. Only once it has achieved this precise texture do we move to cutting these matured blocks into their final shapes. Each piece is tailored to meet the unique demands & preferences of our diverse clientele.
The Mastery of Maturation
This is where art meets science. The cheese sticks are dried for 6-12 weeks, depending on their size and shape. Our dedicated CEO of Kukuje, with his vast knowledge and experience, often personally oversees this process. He also uses advanced instruments to ensure optimal moisture levels
The Quest for Perfection
The moisture content of our chews is paramount. If it's excessive, it poses a risk of mildew, diminishes chew time, and negates the hard chew experience dogs adore. Conversely, if it's scant, the chew becomes fragile. Our commitment to this delicate balance ensures the finest, safest, and most satisfying experience for our furry friends.
The Seal of Quality
Every batch of our meticulously crafted chews undergoes stringent testing in labs accredited by the German veterinary office. These evaluations are exhaustive, covering aspects from protein, fat, fiber, minerals content to checks for salmonella and other microbes.
Approval and Adventure
Once we achieve a stellar lab report, we present it to the official veterinary office – Germany's equivalent of the US-FDA. Upon their approval and issuance of a sanitary certificate, our world-class chews are prepared to embark on their journey to loving homes worldwide.
Shipment
The Journey of Our Premium Chhurpi to Dallas
Once our dog chews have been meticulously prepared, they're securely packed into cartons and placed on pallets. These are then loaded into massive, temperature and humidity-controlled containers, each capable of holding around 16,000 kg of chhurpi. Set to our exact specifications of temperature and humidity, these containers ensure our product remains in pristine condition. With everything in place, our cherished chhurpi embarks on its journey across the vast ocean, destined for our warehouse in Dallas, Texas. Each step is a testament to our commitment to delivering nothing but the best for our customers.
