Pacific Process Projects.
Since 2005, Pacific Process has been constructing food, beverage, and brewery process plants across New Zealand, Australia, the USA, and Canada, with other regions supported from these locations. Project values range from $1 million to $150 million, and the following represent a cross-section of Pacific Process’s more significant projects.
Dairy
Spray Drying Facility
This plant allowed the client to exploit the growing milk volume in the Reno / Fallon NV area and California. Having the milk standardization capability would also allow the client to export WMP & SMP powders internationally and remain competitive (local USA powder cannot be standardized, and as such would not be competitive in the international powder market). Plant ‘state of the art’ and is considered by the client to be their highest quality facility.
Year: 2012 – 2014
Task: Design and supply of Project Management and Engineering for a 6MT/hr WMP Spray Drying Plant.
Where: Fallon, NV. USA.
Value: US$103M
Features: Project included all disciplines required, including:
- Civil and building works
- Milk Treatment & Separation
- Evaporator and Dryer
- Cream Pasteurization, handling and load out
- Powder blending and standardization
- Services (steam boilers, refrigeration, comp’ air, CIP)
Dairy Facility
The facility is designed to reduce the number of trucks for transporting Milk out of Province. All water generated from concentration of dairy product re-used in the facility for cleaning of equipment.
Year: 2023 (ongoing)
Task: Design and supply of Project Management and Engineering for a Manufacturing outlet to supply 300M L/year milk concentrate
Where: Blackfalds, Alberta, Canada
Value: CAD$70M
Features: Project included all disciplines required, including:
- Civil and building works
- Cold processing facility
- Bacterial removal system
- Membrane technology
- Services
Secondary Cheese Processing Plant
This new facility allowed the client to close two other processing facilities (natural cheese cutting plant, and their frozen & natural shredded cheese lines), allowing all of their secondary cheese processing to be completed on one processing site.
Year: 2007
Task: Project management and engineering package to supervise and engineer the new plant.
Where: Eltham, NZ.
Value: NZ$60M
Features: Project included all disciplines required, including:
- Project management and engineering.
- Civil and building works.
- Process design and installation.
- Process line design for processed cheese (IWS & SOS), shred cheese (IQF & Natural) and natural cut
MPC Milk Processing Facility
Plant allows Manitoba dairy farmers the ability to supply all of their milk to the plant. It will produce cream for the Manitoba market, butter for the Canadian market and dry dairy ingredients (milk protein concentrate etc.) for the domestic and international markets
Year: 2017 / 2018
Task: Conversion of an Egg Protein plant to manufacture 150m3/yr MPC
Where: Winnipeg, MB. Canada.
Value: CAD$55M
Features: Project included all disciplines required, including:
- Civil and building works
- Milk Treatment & Separation
- Membranes Systems
- Cream Handling and Butter Plant
- Dryer Upgrade
- Services (steam boilers, refrigeration, comp’ air)
- WWTP upgrade
Butter Processing and Packaging
This facility will produce up to 6 MT of Commodity butter products. On either of two production lines fed from a Single butter churn, using SPX Flex line technology.
Year: Current
Task: Design and Build of a turnkey butter plant
Where: Waharoa, NZ
Value: NZ$30M
Features: Project included all disciplines required, including:
- Civil and building works
- Cream / buttermilk load out
- Cream crystallising silos
- 6 MT/hour Fritz butter plant
- Palletising
IF Plant Management & Engineering
This facility allowed Westland to take the clients DIRA milk, concentrate it and send it to their Hokitika processing plant on the west coast of NZ South Is.
Year: 2012
Task: Project Management & engineering package for WMP Infant Formula plant.
Where: Hokitika, NZ
Value: NZ$25M
Features: Project included all disciplines required, including:
- Civil and building works
- Milk delivery to the IF plant
- Milk storage and handling systems
- Powder handling & dry blending
RO Milk Transfer Station
This facility allowed the client to take DIRA milk, concentrate it and send it to their Hokitika processing plant on the west coast of NZ South Is.
Year: 2012
Task: Design and build of 2ML/day RO Milk Concentration & Transfer Station.
Where: Rolleston, NZ.
Value: NZ$12M
Features: Project included all disciplines required, including;
- Civil and building works
- Milk Receiving
- RO Plant to concentrate the whole milk (VCF 2)
- Milk storage and handling systems
- Rail head load out system
- Services (steam boilers, refrigeration, comp’ air, CIP)
Blenheim Rd Retentate
Year: 2014
Task: 1 storage tank and UF upgrade
Capacity: 2ML/day
Features:
- Product transfer facility to allow permeate production and handling of surplus milk protein concentrate (out-loaded)
- Permeate is retained for local milk production
- UF upgraded to double capacity
Premium Ice-Cream Plant & Freezer
Year: 2004-2005
Task: Detailed design and project management
Capacity: Premium and House brand Ice-Cream in 100ml to 5L containers, up to 3000kg/hr
Value: NZ$10M
Features: Complete new Ice-Cream Processing Plant, building, 28degC Freezer, ingredient stores and associated services including: aging tanks, flavor tanks, powder recombining unit, two low temperature recycle Ice-Cream freezers, two automatic rotary fillers, coding and conveying system, product recovery system, spiral freezer for rapid hardening, semi automatic shrink wrapping, manual palletising and CIP.
Services Plant Projects
Pacific Process have been engaged by the client to carry out general plant upgrades on an ongoing and routine basis. Pacific Process continue to add value to WMP by having personnel permanently stationed on site.
Year: 2007 to present
Task: General plant upgrades in their Hokitika NZ plant (milk treatment, CIP, receiving evaporation, drying and other works).
Where: Hokitika, NZ
Value: Assorted NZ$0.5m to NZ$5m
Features: Projects focussed on utility / services plant with work including;
- Engineering design and cost estimations
- Layout drawings and P&ID updates
- Chilled water plant
- Boiler
- Wastewater treatment
- Civil and building works
- Electrical / automation & mechanical installation works
Process Engineering
E8 Evaporator Project
This new evaporator allowed CDI to maintain constant feed to their two dryers. They previously had just 2 evaporators feeding 2 dryers, so during the daily evaporator CIP, the respective dryer would not be operational, losing significant productivity.
Year: 2016
Task: Project management and engineering package to supervise and engineer the new $68M swing evaporator.
Where: Visalia, CA. USA
Value: US$68M
Features: Project included all disciplines required, including:
- Project management and engineering
- Civil and building works
- Electrical / automation & mechanical installation works
- Process design and installation
IF Powder Blending & Packing Facility
50 cans per minute nominal capacity canning running 900 gm cans line with capacity 2,700 kg / hr. This can line will be fed 24 hours per day without stoppage from the powder handling and blending system. A future can line, nominal 400gm can size, estimated capacity 60 cans per minute, equating 1,500 kg per hour is proposed.
Year: 2018
Task: Design and supply of infant powder handling, blending, 3MT/hr packing and storage equipment for product export.
Where: Shepparton, VIC. Australia.
Value: AU$2.5M
Features: Project included all disciplines required, including;
- Powder transport systems
- Powder packing plant
- Powder handling systems
General Process Plant Upgrades
These general upgrades allowed the client to increase their beverage retort capacity, improve their powder packing capability, increased the production rate and ability to manufacture high heat treated powders through the evaporation process.
Year: 2017
Task: General plant upgrades in their beverage plant, milk treatment, evaporation and drying milk facility.
Where: Batavia, NY. USA.
Value: US$7.5M
Features: Project included all disciplines required, including;
- Civil and building works
- Beverage line retorts
- Powder packing plant upgrade
- Evaporator heat treatment systems
- Dryer pre-heating
- Skim milk and cream handling upgrades
Blending Upgrade
Year: 2019
Task: To increase blending capacity and decrease blending times through expansion allowing multiple concurrent blending of different recipes
Where: Auckland, NZ
Value: NZ$3M
Features: Pacific Process is responsible for all disciplines required including:
- Front-end engineering design
- Procurement, installation and commissioning
- Subcontractor and project
- Develop a hybrid automatic and manual factory operation with provision for future expansion
- Quality assurance in reporting and trending of production
through operation via SCADA system.
KHS CIP upgrade
Year: 2015
Task: Install new caustic tank, modify existing caustic tank to handle re-use water
Capacity: Increase caustic tank from 1,000 L to 3,000 L
Features:
-
Implemented to existing KHS software system
-
Measured medium volumes to lines (metered)
-
Message hints for step requirements
Water
Water Treatment Plant
Year: 2022
Task: Design, engineering and project management of a new water treatment plant.
Where: Huntingwood, Australia
Value: AU$7M
Features: A complete water treatment plant taking towns water at 150m3/hr through a range of treatment steps. The project included:
- Ultrafiltration
- Activated carbon filtration
- A series of storage tanks (100-150m3)
- Design of three ring mains delivering water to a range of fillers andher end users around the production plant
- All automation and control systems
- All installation works and overall project management
Spring Water Processing Plant
This new facility allowed the client to produce 50m3 / hr of beverage quality drinking water. The water was bottled using Krones proprietary filling equipment
Year: 2017
Task: Full turnkey spring water processing
plant turnkey design and build.
Where: Sydney, NSW, Australia.
Value: AU$6M
Features: Projects generally included all disciplines required, including;
- Project management and engineering
- Site installation works
- Micro filtration and carbon filtration systems
- Ozone treatment
- Process design and installation
Hot Water Supply Upgrade
Year: 2023
Task: To drop hot water loop temperature from 95° to 85°
Where: Palmerston North, NZ
Value: US$2.5M
Features: Project included all disciplines required, including;
-
Subcontract tendering and delivery of the
complete project -
The MCC upgrades and required tie-ins were installed over a carefully managed 8 hour shut-down window
-
As a liquid milk plant, the FBNZ plant generally
never shuts
Beverage / Alcohol
Beverage Plant Upgrade
Plant allows Manitoba dairy farmers the ability to supply all of their milk to the plant. It will produce cream for the Manitoba market, butter for the Canadian market and dry dairy ingredients (milk protein concentrate etc.) for the domestic and international markets.
Year: 2012
Task: New beverage manufacturing facility for manufacturing milk protein fortified beverages.
Where: Batavia, NY. USA.
Value: US$8.5M
Features: Project included all disciplines required, including;
- Civil and building works
- Powder handling and dumping
- Powder blending
- Beverage storage & distribution to 3 x filling lines
- CIP systems
- RO Beverage water system with UV sterilization
Fermenter Tank Upgrade
Year: 2020
Task: Design, supply, installation, testing and commissioning of replacement fermenter tanks and clean-in-place systems (CIP)
Where: Auckland, NZ
Value: NZ$5M
Features: Pacific Process is responsible for all disciplines required including:
- Project Management and Strategic Business Development
- Project and Contract administration
- Financial Management and Control
- Process Engineering, Project Engineering
- Electrical and Control Engineering, Civil and Structural Engineering and Waste Water Engineering
- Construction Management
- Commissioning and Training
Gin Distillery
This new facility allowed the client to produce 50m3 / hr of beverage quality drinking water. The water was bottled using Krones proprietary filling equipment
Year: 2022 – 2024
Task: Process design and integration
Where: Wanaka, NZ
Value: NZ$6.5M
Features: Project included all disciplines required, including;
- Building construction and design co-ordination with the plant and process design
- Selection and specification of utilities and other services
- Distillery installation and co-ordination of sub-contractors
Brewery Upgrades
Year: 2019
Task: An upgrade to the existing facility allowing design and/or installation of a range of improvements to throughput and efficiency.
Where: Auckland, NZ
Features:
- Develop PIDs, piping Isometrics, and layouts for the integration of these new works.
- Sugar Storage and transfer to batch tanks. Upgrades to the dissolved oxygen water plant (DAW) and increasing storage capacity to 50m3.
- Installation of a centrifuge for the clarification of fermented beverages, plus a liquid blender for combining raw beverage flows post filtration.
- Syrup room Safety/ Quality and compliance upgrades, including a HSNO compliance report.
Beverage Plant Upgrade
Year: 2018
Task: New beverage manufacturing facility for manufacturing milk protein fortified beverages.
Where: Batavia, NY. USA.
Value: US$8.5M
Features: Project included all disciplines required, including;
- Civil and building works
- Automation for the complete installed plant
- Chilled water plant and reticulation
- Compressed air
- Hot water system
- Beverage storage & distribution to 3 x filling lines
- CIP systems
- RO Beverage water system with UV sterilization
Syrup pasteuriser
Year: 2015
Task: Turnkey pasteuriser with additional holding tank
Capacity: 5,000 L/hour
Features:
- Pasteurisation of syrups to buffer tank prior to pre-mixer supply
- Buffer tank dual purpose as holding tank for non-pasteurised products
- Modifications to allow mineral water supply to pre-mixer
- Glucose and dextrose handling systems
211 Can Line
Year: 2010
Task: Turnkey syrup and DI water handling to service Krones pre-mixer and filler Inclusive of additional CIP supply from existing kitchen
Capacity: 20,000 cans/hour
Features:
-
Upgrade of batching plant with additional 30kl batching tank and a new sugar tank
-
Syrup transfer line to 2 x 30kl holding tanks
-
Syrup transfer to Krones pre-mixer/filler
-
Installation of ion exchange plant for DI water
-
DI water storage and transfer to pre-mixer
-
Services installation to plant and Krones equipment
PET CSD Line
Year: 2012
Task: Water handling to service Krones blow moulder, pre-mixer and filler. Inclusive of an additional CIP supply from the existing kitchen
Capacity: 28,000 bottles/hour
Features:
-
Upgrade of batching plant with 3 replacement batching tanks and a 60T sugar tank
-
Syrup transfer line to 2 x 35kl holding tanks
-
Syrup transfer to Krones pre-mixer/filler
-
Installation of ion exchange plant for DI water
-
DI water storage and transfer to pre-mixer
-
Services installation to plant and Krones equipment
-
Installation of additional CIP supply system
General Process Plant Upgrades
These general upgrades allowed the client to increase their beverage retort capacity, improve their powder packing capability, increased the production rate and ability to manufacture high heat treated powders through the evaporation process.
Year: 2017
Task: General plant upgrades in their beverage plant, milk treatment, evaporation and drying milk facility.
Where: Batavia, NY. USA.
Features: Project included all disciplines required, including;
- Civil and building works
- Beverage line retorts
- Powder packing plant upgrade
- Evaporator heat treatment systems
- Dryer pre-heating
- Skim milk and cream handling upgrades
Waste
Waste Treatment Facility
This plant was built to support the WMP spray drying facility described in the previous slide.
Year: 2012 – 2014
Task: Design and supply of Project Management and Engineering for a 6MT/hr WMP Spray Drying Plant Waste Water Treatment Plant.
Where: Fallon, NV. USA.
Value: US$7.5M
Features: Project included all disciplines required, including;
- Civil and building works
- WWTP lift station, EQ & Calamity Tanks
- Primary and secondary DAF
- MBBR systems with aeration
- Sludge storage, de-watering (screen) & load out
- WWTP chemical systems
Wastewater Treatment
Year: 2016
Task: Coordination of the design, equipment supply, installation management and plant commissioning for a wastewater treatment facility.
Where: Rolleston, NZ
Value: US$7.5M
Features: The project scope included;
- Trade waste balance tanks.
- Tank instrumentation and agitators.
- Automation and controls around wastewater discharge
- pH and temperature control
- Flow control
- Caustic and sulphuric acid storage and dosing
- Wastewater sump and sump pump