The professionalism and commitment of FPC throughout the project has been a highlight for us. We specifically wish to acknowledge your team’s commitment to safety, attention to quality, and excellent collaboration with the project community including Tatua’s wider team.

FPC has been an outstanding project partner and has very directly contributed to the delivery of a high-quality facility that we are all extremely proud of and that will serve Tatua well into the future.

Brendhan Greaney Tatua Chief Executive

Project Overview &
The Challenge

The Tatua Co-operative Dairy Company Cream Plant Extension project was an $85M strategic expansion of Tatua’s processing facility, designed to boost specialty cream production and strengthen the company’s ability to meet growing global market demand. FPC’s $25M scope included the development of a new cream processing area, palletiser, warehouse, and an adjoining admin facility for over 100 staff, all seamlessly integrated with the existing plant.

While the base design provided a strong foundation, the client’s commitment to securing both value for money and programme certainty inspired a proactive approach to project delivery. FPC was engaged to implement a series of design enhancements reflecting the client’s market-driven requirements. This collaborative process fostered agility, enabling the team to respond swiftly to evolving needs. The successful management of these changes meant up to 20 trades could be effectively coordinated on site at once, ensuring seamless progress despite the project’s complexity.

Time was identified early as a critical constraint. FPC responded by compressing the schedule and focusing on key milestones to maintain momentum and uphold the client’s confidence in the project’s successful delivery. This required integrating structural designs and process installation, constantly adjusting sequencing and contractor schedules, and ensuring progress never stalled.

An unexpected three-week delay in structural steel delivery posed a significant risk to the timeline. FPC mitigated this by re-sequencing the programme, shifting focus to panel installation and other critical areas to keep the project on track.

Adding to the complexity, construction had to proceed alongside a fully operational dairy plant. With only a brief planned shutdown window, meticulous planning was essential to avoid disrupting production or compromising the stringent food-grade hygiene standards.

The Solution

FPC adopted an agile and collaborative approach to design and delivery to meet the client’s tight timeline. Engineers and planners worked closely with Tatua’s team to swiftly incorporate evolving design decisions, even as construction progressed. Every late-stage adjustment, from equipment layout refinements to structural modifications, was handled through rapid drawing revisions and approvals, ensuring minimal disruption to the programme.

A critical focus was seamlessly integrating new facilities with existing infrastructure, warehouses and utilities within a tight footprint. To achieve this, FPC implemented Autodesk BIM 360 as a central coordination platform, enabling proactive digital planning and real-time collaboration across all trades. By overlaying architectural, structural, mechanical, and electrical models, the team identified and resolved potential clashes virtually, synchronising key services such as ventilation, fire protection, power and data. This significantly reduced rework and kept the build efficient under challenging conditions.

When unforeseen issues arose, such as clashes between new structures and existing piping, they were resolved quickly through a combination of on-site problem-solving and digital coordination. FPC’s solution focused and “find a way to keep moving” mindset ensured the project remained on track, despite late design changes and material delays.

Throughout the build, safety and quality remained paramount. Operating within a live food production environment, FPC worked closely with Tatua’s operations team to isolate work zones and implement thorough cleaning procedures adhering to the strict hygiene protocols.

Rigorous safety oversight was maintained at all times, and despite the accelerated pace, no serious incidents occurred. Subcontractors praised FPC’s high level of planning and organisation, which enabled everyone to work efficiently, safely, and with confidence.

The Value

On-Time, On-Budget Delivery: Despite early delays and design finalisation activities, the project was completed on schedule and within budget through adaptive planning and sequencing.

Digital Precision: FPC’s use of BIM 360 for digital project management transformed coordination on site. By integrating building services in a unified 3D model, the team minimised rework and streamlined delivery.

Quality and Performance: The new facilities met all Tatua’s high quality standards.

Collaboration & Relationships: The project strengthened relationships across the board, fostering open, honest communication and a collaborative culture between FPC, Tatua, and all partners. Navigating challenges together built trust and created a genuine sense of partnership well beyond the typical client-contractor dynamic. Delivering another successful project for Tatua is a testament to this trust. We’re proud to have worked with them again and repeat clients remain one of our ultimate measures of success.