Open Country Dairy — Design and Build of WPC Building Extension

When First Principles Constructors (FPC) was engaged to deliver the design and construction of a Whey Protein Concentrate (WPC) building extension within an operational facility in Waikato, we knew we were stepping into a fastmoving, high-pressure environment. Open Country Dairy is a leading player in the New Zealand dairy industry and required delivery within a strict timeframe, leaving little room for upfront planning and no margin for error.

The extension was critical to enable the relocation of key processing equipment and maintain uninterrupted operations. Any delay or misstep would have had direct implications on production continuity.

The site itself presented its own set of challenges. As a brownfield location, it carried significant risk due to unknown and buried services. Navigating this required careful sequencing, flexible construction methodologies, and rapid decision-making to keep the project moving.

FPC approached the design phase with a strong emphasis on integration, ensuring that the process contractor’s needs were understood, and the revised manufacturing process would be functional in the available space. This included confirming that relocated equipment seamlessly fit within the
extended facility.

Next came the programme challenge. Sequencing and access requirements were key, and FPC stayed ahead of the game by devising a clever consenting strategy that enabled initial trades to get boots on the ground, whilst working through design and procurement in other areas. To facilitate the process
contractor’s needs, FPC strategically kept certain areas of the building clear, ensuring uninterrupted access for equipment deliveries and installations.

It’s no easy feat maintaining existing processing operations whilst connecting a new building into an existing. FPC managed this meticulously, upgrading the hygiene change area to accommodate factory workers, and keeping plant rooms running. We also factored in the re-use of equipment from an existing plant at the facility, removing a 625m2 roof to facilitate this. This meant coordinating a large crane that could manage the 40m reach to dismantle, undertaking night works and juggling trades to ensure production wasn’t impacted. This was a smart, sustainable, cost-effective solution for the client.

• Delivering at Pace: FPC’s strong team support and proactive management ensured the project was delivered a month ahead of schedule.
• Operating in Live Environments: The FPC Small Works team have a deep understanding of our client’s requirement to keep their production wheels turning. The team are also strongly committed to upholding hygiene requirements and considering traffic flows and people movement in their methodologies.
• Process Contractor Integration: We completed a swift assessment of the process contractor’s requirements, particularly in relation to the existing equipment and available space.