Open Country Dairy — D2 Powder Plant Building Upgrade

Open Country Dairy needed to increase the capacity of their D2 milk drying tower – and they needed it fast. When First Principles Constructors (FPC) were engaged to lead the structural design and integration of new stainless-steel hoppers and access platforms, we knew it was a high-stakes environment.

The tower stood 25–30 metres tall, operating at high heat with strict hygiene protocols, and the upgrade had to be delivered without disrupting ongoing production.

Working inside an operational drying tower came with significant challenges. With no crane access to lift multi-tonne platforms within a structure never designed for internal hoisting, space was extremely limited.

This is our Small Works team’s specialty; a project requiring clever planning and sequencing to operate in a live environment, with limited space and strict hygiene protocols.

From the outset, the team focused on seamless integration, engineering every structural element to suit the constraints of a dense, fully operational milk drying tower.

With an existing powder bin occupying space within the tower, we leveraged our technical expertise to develop smart design solutions to enable construction in a condensed space. Our solution was breaking the platform to be installed into modular, “Lego-like” components pre-assembled offsite, then reassembled on location in tight quarters. This allowed install to proceed whilst maintaining plant operations.

With no crane access inside the tower, we then had to solve how to lift the multi-tonne platforms. We engineered a smart lifting system, utilising temporary strengthening and incorporating transfer structures to lift sections of the new platforms and powder bins into place. As clashes emerged with existing systems, the team adapted in real time, modifying beam positions, designing gusset plates, and incorporating transfer structures to safely manage the added loads.

• Off Site Prefabrication: We knew building off site and re-assembling would solve a complex logistics issue presented by limited space in the existing tower.
• Innovative Engineering: Our engineers are some of the best in the business. We come up with smart temporary works and lifting solutions, to facilitate building to programme, with safety at the forefront.
• Challenging Working Conditions: These works were completed in tight quarters, in a live environment, in high heat (with the HVAC switched off). No sweat for the Small Works crew.
• Coordination with Process Contractors: We understand the needs of process contractors and how to integrate their equipment and install methodology seamlessly.