Project Gold Dust

Westland Dairy, a major player in the dairy industry, embarked on an ambitious journey to modernise its aging lactoferrin plant on the West Coast, a project aptly named Project Gold Dust.

The project aimed to significantly increase the plant’s capacity to process lactoferrin, a high-value protein in significant demand globally for its use in health supplements.

Westland Dairy turned to FPC to achieve this, a construction firm with a proven track record in the dairy sector. This case study highlights the challenges and the innovative construction solutions developed by FPC to deliver this build on time and on budget.

The original lactoferrin plant at Westland Dairy was over two decades old and struggled to meet modern standards and product demand. The goal? To increase the plant’s processing capacity from 20 to 70 metric tonnes per year, a monumental leap that required state-of-the-art technology and equipment. According to Phil Law of Westland Dairy, the old plant’s inefficiencies necessitated a complete overhaul, from new processing methods to advanced equipment, including freeze dryers and spray dryers.

FPC was not new to Westland Dairy, having already completed a butter plant project next door to the Lactoferrin plant. That project was aptly called Project Goldrush, a nod to the West Coast’s heritage.

The decision to engage FPC again was influenced by their demonstrated ability to deliver high-quality projects under tight timelines.

FPC’s credibility, experience, and familiarity with dairy industry standards made them the ideal choice.

“They know how to build them quickly and to meet stringent quality and MPI requirements,” Phil Law from Westland Dairy notes, highlighting FPC’s unique capability to work efficiently without constant oversight.

One of the primary challenges of Project Gold Dust was the need to coordinate with multiple subcontractors while ensuring that the project stayed on schedule. Unlike previous projects where Westland Dairy managed the contracts directly, this project required FPC to handle significant coordination efforts.

FPC’s approach to designing and fabricating components off-site played a crucial role in maintaining the project’s momentum. This strategy, combined with their ability to force timely decisions from all stakeholders, ensured that the project remained on track.

The FPC methodology involves overlapping tasks and working closely with process contractors. This approach allowed FPC to sequence their work effectively, maintaining progress even under challenging conditions.

“We often stack our programs, so we won’t finish one task before starting another. This way, we can run in conjunction with other processes,” FPC’s Jason Armstrong explains.

FPC’s strengths were evident throughout the project. Their ability to design quickly, get approvals efficiently, and fabricate off-site minimised delays. Their proactive communication ensured that all parties were aligned and accountable, a crucial factor in the project’s success.

Jason Armstrong notes that FPC’s extensive experience in the dairy industry allowed them to understand and anticipate the needs of the process contractors, further streamlining the build.

Additionally, FPC’s use of trusted subcontractors, many of whom travelled with FPC from previous projects, ensured a high level of quality and reliability. This network of skilled professionals, combined with FPC’s rigorous oversight, resulted in a seamless construction process despite the geographical and logistical challenges of the West Coast.

Project Gold Dust stands as a testament to FPC’s expertise and efficiency in the dairy industry.

By modernising Westland Dairy’s lactoferrin plant, FPC not only helped increase production capacity but also ensured that the facility met contemporary standards and demands.

The success of this project underscores why Westland Dairy continues to rely on FPC for its most critical builds. With a focus on quality, speed, and innovative problem-solving, FPC has once again proven itself as a leader in dairy construction, making complex projects look simple.