Fonterra Hautapu

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Fonterra’s Hautapu site, a cornerstone of the Waikato region for over 120 years, embarked on a transformative project last year to modernise its chilling systems.

The goal was to replace the outdated R22 refrigerant with a more environmentally friendly ammonia system. Part of a nationwide effort to phase out R22 from all its sites, Fonterra aims to be a leader in environmental standards without sacrificing its expertise in high-value products.

Having worked previously with Fonterra, FPC is a specialist in undertaking such complex projects, and its work has been instrumental in helping the dairy co-op meet sustainability and operational goals.

The Hautapu site required a significant upgrade to its chilling infrastructure to improve its environmental impact, transitioning to ammonia after relying solely on R22 refrigerant.

Commencing in 2023, the scope of the project included installing foundations for three new GEA chiller skids, two cooling towers, two 80m³ silo’s, and additional infrastructure to support these systems. This involved not just upgrading the chillers but also constructing a new Master Control Centre (MCC building) and installing transformers to meet increased power demands.

One of the primary obstacles was dealing with the plant’s existing infrastructure. Numerous and previously unknown underground services, which were not fully documented, led to some unexpected complications. FPC’s meticulous planning and flexible problem-solving helped the team adapt and manage these issues without significant delays to the project timeline.

Integrating the new systems with the existing infrastructure, however, particularly the trade water system, posed a challenge. FPC demonstrated innovative thinking by proposing a cost-effective solution that involved modifying the existing sumps to meet current standards and ensure compliance, rather than constructing new ones. This approach reduced costs and minimised the disruption of existing operations.

While the project timeline experienced some delays, notably due to foundation work and holiday periods, FPC showed flexibility by adjusting its schedule to accommodate other contractors and maintain overall progress. They also ensured that any changes or delays were communicated quickly, allowing for timely adjustments and a coordinated approach to project completion.

FPC was chosen for this project due to their comprehensive and well-structured proposal. Their attention to detail and clarity around the costs and process breakdown was also a standout. However, it was their communication and ability to think on their feet that saw them provide Fonterra with the most value.

FPC’s project management team were articulate and seasoned at devising mitigation strategies. Adjusting their construction schedule and milestones to accommodate the overall project timeline showed their flexibility.

On a day-to-day basis, FPC’s innovative thinking and creative (and costeffective) solutions were highly valued. They maintained a high level of professionalism and responsiveness, from managing on-site issues to handling invoicing and project forecasting. Their ability to deliver on their comprehensive proposal while adapting to the project’s evolving requirements was priceless.

The successful completion of the Hautapu site’s chiller upgrade marks a significant milestone in Fonterra’s commitment to sustainability. FPC’s expertise and innovative approach played a critical role in achieving the project’s objectives.

Their work not only modernised the plant’s infrastructure but also contributed to a more environmentally friendly and efficient operation, reinforcing Fonterra’s leadership in sustainable dairy production.