Fonterra Kauri – Dryer HVAC Upgrade

Delivered within the tight constraints of the winter shutdown, Fonterra required crucial HVAC upgrades to the Dryer Building at their Kauri processing site. This build only project involved intrusive construction works including; large scale scaffolding and temporary works to allow the controlled removal of concrete wall penetrations, structural steel installation, new walls, ceilings and duct work inside the dryer building.

Working inside an active dryer building comes with significant challenges: with confined work zones, strict hygiene protocols and cleaning procedures – practical pre-project planning, smart sequencing and innovative solutions to meet the completion date was critical for milk processing and production to restart.

FPC Small Works delivered the upgrade using a structured shutdown-focused methodology. With
most of the construction works being required at height, scaffold systems were scoped and erected ahead of the winter shutdown to enable construction access and weather mitigation during wet winter conditions.

A part of the project involved cutting large wall penetrations into reinforced concrete wall panels and the addition of structural steel framing, to make way for new air handlers and large ductwork inside the factory. The next part of the project saw a new pop-top air intake, constructed on the roof of an existing building using structural steel, insulated panels, colorsteel roofing, and flashings. Limited lifting access was overcome through scaffold towers, temporary monorail hoists, and temporary strengthening to manoeuvre air handler components safely into position.

Real-time adjustments were made as clashes emerged between new and existing plant elements, with the team modifying steelwork, adjusting duct pathways, and coordinating live with separate contractors to maintain programme momentum.

• On time winter shutdown delivery: Completed safely and in full within the time-pressured winter shutdown, enabling production to restart on time with no disruption.
• Speed and precision in a live environment: FPC Small Works delivered complex industrial construction solutions in a live environment, with smart, efficient and high-quality execution.
• High quality performance and compliance outcomes: Improved HVAC performance and airflow reliability, with durable upgrades and zero hygiene breaches.