Fonterra – Powder Packing Ceiling Replacement

FPC was engaged to help resolve an issue in the Powder Packing room, providing rapid diagnosis of the root cause and a practical, timely solution.

Site investigations by FPC quickly identified that the existing ceiling structure in the Powder Packing room was driving poor performance of the Heating, Ventilation, and Air Conditioning (HVAC) system.

The challenge was designing a compliant solution, securing materials, and completing the build – all within the narrow window of Fonterra’s winter shutdown, before production resumed. This gave us a seven-week window to plan, design and execute the works – with just three weeks available for install.

We designed a new sealed ceiling system that would guarantee HVAC performance. The product was Food Manufacturing approved to meet FSQ compliance. Subsequently this ceiling system was installed on site with improved specification of lighting and new sprinkler heads – bringing all elements up to Fonterra’s Engineering Standards.

The solution ensured the room could hold the necessary pressure, enabling the HVAC system to deliver the required efficiencies.

• Rapid mobilisation: We responded swiftly to the client’s urgent timeline, undertaking an exceptionally quick assessment and assembling the team and securing materials in time to meet the shutdown schedule.
• Compliance-led design: Our ability to identify the root issue and engineer a compliant ceiling solution ensured the room met FSQ standards and supported HVAC performance. This ultimately resulted in a more efficient and better performing room for the client.
• Maintaining production: The project was completed within the maintenance shut period and handed over without defects – minimising disruption and ensuring a smooth return to production.