Synlait owns and operates one of the main dairy plants in
Canterbury, New Zealand. A recent boom in the dairy industry has
seen large dairy companies expand their facilities to keep pace. As
a result, smaller companies such as Synlait have had to follow
suit, in a bid to remain competitive.
Apollo engaged GHD to assist with the Design and Construct of a
new baby formula blending and canning plant. The objective was to
deliver a solution focused on the need for the Chinese clients to
regularly view the plant, meet and exceed hygiene specifications,
and safeguard food security and traceability whilst taking into
account the latest technology and robotic design.
Our team provided the preliminary design of process, structure
and architectural facilities. In addition, we produced a
geotechnical testing and interpretative report, carried out
detailed design and detailing, and provided construction
With early contractor involvement, our team developed the most
cost-effective design. Integral to this, was fitting the blending
and canning process to the building, and meeting strict industry
hygiene requirements. The plant includes a 60 by 30 m building with
a 22 m high blending tower.
The building was considered a complex structure due to its
unusual shape – structurally it covers five levels, although
physically it appears to be just two. Inside there is a viewing
gallery for visitors, highly sophisticated continuous blending and
canning equipment, and robotic product stacking capabilities.
The final outcome is a factory that produces tins of high-value
infant formula for export using state-of-the-art hygiene detailing.
This has established a benchmark for Synlait to have its other
contractors meet higher hygiene detailing requirements.