Olam Food Ingredients (ofi) – Whole Milk Powder Plant

Building a world-class whole milk powder plant in Tokoroa, Olam Food Ingredients (ofi), one of the biggest names in dairy, knew FPC was up to the task.

This was no ordinary project. With a budget of $44 million and a delivery window of just 18 to 20 months – right in the middle of the COVID-19 pandemic – the team faced a tall order. They were tasked with transforming a former sawmill site into a cutting-edge milk powder facility including a Dryer Tower, Boiler and Fuel Bay.

Early site conditions added complexity: contaminated soil, volcanic rock, and remnants of timber waste required remediation before construction. FPC managed the ground improvement beneath the building footprint, carefully removing unsuitable materials down to bedrock and methodically rebuilding a stable platform.

One of the biggest challenges was the sheer number of precast panels, creating a potential bottleneck in production. Hundreds of panels needed to be manufactured off-site in Tauranga, tracked, and installed.

And, as if that wasn’t enough, the site’s location added another layer of complexity, with railway tracks, a major highway, and nearby homes all creating logistical and noise challenges.

Throughout, FPC maintained strict food safety standards, especially in sensitive areas like the packing room where a rigorous snagging and close-out process was essential to ensure quality.

From day one, FPC made collaboration the cornerstone of their approach. Working hand-in-hand with ofi, GEA and all project partners to make sure everyone was on the same page.

The design process was highly dynamic. The team successfully coordinated 3D models across multiple software platforms, integrating Bentley and Revit outputs to create effective workflows that kept information aligned and supported timely decision-making. This collaborative approach strengthened coordination across disciplines and played a key role in sequencing building works alongside process equipment installation.

A detailed precast tracker was developed to manage casting rates, storage, delivery, and coordination between three separate precast trades, avoiding resourcing bottlenecks. As a result, all 685 precast elements were cast and installed on schedule, with zero rework or post-pour modifications.

During construction, FPC introduced a specialised flooring system that could be installed more quickly and was less affected in wet weather, helping maintain programme certainty. Consenting was strategically managed through a staged, responsive approach, applying for foundation and other consents as needed and working closely with Council to keep things moving smoothly.

Recognising that final project stages are often the most challenging—particularly in hygiene-critical areas such as the packing room—FPC deployed a fresh dedicated close out team focused solely on resolving outstanding issues, ensuring a high-quality finish and full client satisfaction.

• Delivering under pressure: The results speak for themselves. The new plant was delivered on time and on budget, with more than 200,000 site hours worked and not a single lost time injury. The facility has supported ofi’s growth in the region and paved the way for future expansion.
• Partnership: The project also strengthened relationships across the board, fostering a culture of open, honest communication and collaboration between FPC, ofi and all involved partners.
  Innovative planning: Early collaboration, proactive design management, and robust change control were key to success. These lessons have since become embedded in FPC’s approach to every project.
• Partnering with the community: The transformation of a disused industrial site into a state-of-the-art food processing facility has delivered new opportunities for Tokoroa – addressing environmental and logistical challenges with care and responsibility.
• Project close-out: The construction crew demonstrated exceptional efficiency during close-out, maintaining high standards and unwavering dedication through to the final handover.