Fonterra Clandeboye Mozzarella Plant, New Zealand
Aurecon and partners take a collaborative approach to Fonterra's Clandeboye plant, using 3D modelling to modularise their cheese-making process.
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Fonterra is on a journey of decarbonisation, with an ambition to net zero emissions by 2050, a 50 per cent reduction in absolute emissions by 2030, and to cease coal use by 2037.
Waitoa was Fonterra's third manufacturing site to reduce coal use last year, with a new 30 MW biomass boiler being installed to replace an existing coal boiler. The new biomass boiler reduces the sites annual emissions by a forecast 48,000 tonnes of CO2e the equivalent of taking approximately 20,000 cars off New Zealand’s roads and is another significant step in Fonterra’s transition to a low carbon future.
Waitoa represents a significant milestone in Fonterra’s ambition to lead in sustainability and decarbonise its operations.
Aurecon's Manufacturing team took on the role of technical consultant and project manager for the Waitoa Biomass Boiler Project. This role included technical teams in the geotechnical, and civil design of the new plant along with the mechanical, electrical, structural design to integrate the Windsor Energy turn-key boiler scope with existing site infrastructure.
The Fonterra Waitoa site has been in operation for over 100 years, making the new boiler construction process challenging. With many historical services criss-crossing the site, installation of the pipe bridge was complex.
Aurecon’s design of the 400 m pipe bridge included full off-site construction, with individual pieces transported to site to be put into place. The pipe bridge was designed in modular sections, at most 25 m long and 2 m wide, which enabled offsite manufacture and easy transportation to site.
The pipe bridge carries all main services to the boiler site from the existing Fonterra site, as well as carrying the 'green steam' back to the processing plants. Green steam is an anecdotal term for industrial steam produced without using coal.
The 11 kV power distribution system is linked to the process / mechanical design of the plant through a specialist design.
This project was executed by a fully integrated project and construction management team, with Aurecon’s technical experts working closely alongside key Fonterra team members.
The team worked collaboratively with Windsor, Schick, HME and Fonterra to generate detailed work package plans which provided effective communication of construction activities to the site operational teams and all contractors. The combined team of Aurecon, Fonterra and contracting staff was able to work positively together to meet all project goals and deadlines.
In September 2023, the project team celebrated first 'green steam' production, on time and to schedule.
The project won Environmental, Social, Governance (ESG) Project Transformation of the Year at the 2024 Project Management Institute Awards. This award recognises projects that have excelled in demonstrating ESG principles by incorporating sustainable practices and considering the environmental, social and governance aspects throughout its life cycle.
Fantastic recognition for Fonterra, Aurecon, Windsor, Schick and HME.
The project has won the following award:
Aurecon and partners take a collaborative approach to Fonterra's Clandeboye plant, using 3D modelling to modularise their cheese-making process.
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