Designing the largest UHT plant in New Zealand

Increased global consumer demand for dairy products led Fonterra to construct a new, modern and high-performing greenfield UHT plant in Waitoa.

Capable of filling up to 100,000 packs of UHT milk an hour and processing over 100 million litres of milk a year, the 15,000m² plant was designed, constructed and commissioned within a challenging 12 month period - thanks to the efforts of a collaborative, integrated team.

Built next to Fonterra's existing Waitoa site, the plant needed tie-ins to existing service supply systems - and the team also had the challenge of working around an operating facility.

Our team was engaged to do the concept study in conjunction with Tetra Pak and Fonterra, including a bulk and location study, logistics, evaluating the utility needs, plant layout, building features, civil design, geotechnical analysis and cost estimating. We also prepared contract documentation and led the process services design.

As part of an integrated Fonterra, Beca, Tetra Pak and Ebert project management team, we also provided design management, contract management, services construction management and interface management. Our design management function included leading extensive review sessions and HAZOP workshops for all aspects of the Tetra Pak and Beca designs.