Our overall approach to the project was to bring together the right people with the right experience to deliver a technically challenging project.

Affco Wairoa

AFFCO Wairoa processing plant employs approximately 650 people, operating over two shifts processing lamb, mutton, goat and beef for all major markets across the globe.

The plant is a mainstay of the local community and AFFCO continues to invest significantly in the plant. In 2022 FPC were contracted to build a new Carton Buffer Tunnel, Blast Freezer and Engine Room.

1. The Carton Buffer Tunnel

The Carton Buffer Tunnel comprises a 5.70m wide x 73.8m long x 11.20m high refrigerated space with automated multiple level racking and conveyors.

2. The Blast Freezer

The Blast Freezer is a 11.80m wide x 40.60m long x 11.2m high freezer which operates at -33 degrees Celsius and includes a steel modular storage system, conveyors and Control Room.

3. The Engine Room

The new Engine Room required the demolition of existing buildings prior to the construction of new reinforced concrete foundations and a precast concrete superstructure. The Engine Room included a Control Room and a MCC Room.

FPC completed a detailed coordination of the precast shop drawings to the wall and floor penetrations in the Engine Room.

The early coordination of the specialist suppliers drawings, with the service subcontractors, allowed the major penetrations to be constructed within
the panels prior to site delivery.

Our team faced a number of key challenges in delivering the scope of works:

  1. Unidentified below ground
    obstructions and infrastructure
  2. Working within an operational
    meat processing plant 
  3. Constrained site bounded by existing
    operational buildings
  4. Logistical constraints including
    deliveries, laydown spaces and
    maintaining staff pedestrian
    access routes
  5. Food hygiene requirements and
    Covid disruption
  6. Materials supply and subcontract
    resource constraints
  7. Inclement weather
  8. Integration with existing structures
    and services

The project was undertaken over a 51 week programme including the automated racking, conveyors and refrigeration which was installed by the client appointed specialist subcontractors.

Our key learnings:

1. Work in partnership

It was our belief that working in full partnership with AFFCO from the beginning and drawing on the teams experience, we were able to fully understand the client’s requirements – thus ensuring we reduced or eliminated risk.

2. Communication is vital

A major step in ensuring the journey of the project was an enjoyable process was the communication. It was an important part of the project for the FPC team members to establish relationships and communication both up, and down stream, with AFFCO. Through these relationships we developed an understanding of the significance of the project and consideration for the client’s requirements and goals.

3. Select the right sub-contractors

Our supply chain partners were essential
to the delivery of the project. The FPC project team strategically identified
sub-contractors, specialists and suppliers that we knew were capable of delivery not only in terms of quality, but also in terms of providing us with appropriate resources.