Engineering a future-ready production line for a confectionary warehouse
At a glance
A Global confectionary manufacturer needed to expand production capabilities by converting existing warehouse space into a temperature-controlled, dual-room production line. We delivered integrated engineering and design services from concept through construction support that enabled our client to launch a new product line while improving sustainability and operational efficiency.
The challenge
To bring a new product to market, our client, a leading innovator in the global confectionary landscape, needed to transform a section of their existing facility into a purpose-built production space. The goal was ambitious: repurpose a 5,400-square-meter warehouse footprint into two separate rooms, a preparation area and a packaging area, each with distinct temperature requirements.
GHD’s client prioritized sustainability and cost-effectiveness, aiming to reuse existing infrastructure while improving energy efficiency. Modifications needed to occur within an active manufacturing environment without disrupting operations, requiring a balance between new infrastructure and existing assets.
We were engaged to provide end-to-end engineering and design services across process, electrical, mechanical, structural and architectural disciplines, with a focus on practical innovation, precision planning and seamless project delivery.
Our response
Our long-standing partnership gave us deep familiarity with the facility's systems and operations. We began with site visits and concept development, creating piping and instrumentation diagrams, single-line diagrams and layout drawings that were approved before moving to preliminary design.
Throughout the design process, we prioritized efficiency and sustainability. We designed closed-loop hot- and cold-water systems to repurpose waste heat and support process temperatures of 50°C, 5°C and 1°C, significantly improving energy performance. Rather than installing new heating, ventilation and air conditioning (HVAC) systems, we modified existing ductwork to maintain clean airflow and achieve precise climate control while minimizing environmental and financial impact.
To reduce costs, our design incorporated existing power panels, lighting, HVAC systems, insulated metal panels and doors. We also coordinated early with public permitting authorities to streamline approvals and prevent delays, keeping the construction timeline on track.
The design process culminated in a comprehensive tender package, including technical documents, specifications and a detailed scope of work. During construction, we continued supporting our client as the engineer of record, reviewing Requests for Information, responding to contractor submittals and conducting engineering inspections.
The impact
The new production area has transformed our client's capabilities, enabling a successful new product launch while demonstrating their commitment to manufacturing innovation. Our design increased production capacity and delivered long-term sustainability through strategic reuse of infrastructure and energy-efficient systems. The integrated, client-centered approach ensured successful delivery while establishing a foundation for future facility upgrades that prioritize efficiency and scalability.
By creating a space where efficiency, sustainability and innovation converge, this project provides lasting value for our client, the community and the environment.