CASE STUDY 10 JUNE 2017 FT309 NEW FACILITY DESIGN ENHANCES Waikato Valley had cultivated an early relationship with fellow Waikato entity Apollo Projects, a specialist in the design and construction of food and beverage facilities. It wasn’t rocket science to link its redevelopment plans with the expertise and ability of Apollo Projects to develop the specialist design and ultimately construct the new facility. The potential move to a greenfield site provided an ideal opportunity to rethink the production and logistics process, and significantly increase the operation’s efficiency, Waikato Valley Chocolates director Hans Vetsch says. Apollo’s focus from the start incorporated a detailed understanding of the specific needs of each section of Waikato Valley’s operation, working collaboratively through various scenarios and providing appropriate advice on the various design options. Waikato Valley Chocolates is jointly owned by The Warehouse Group and several private shareholders, which meant each party had different requirements in terms of project approval, Apollo business development manager Grant Black says. “Apollo’s detailed design and feasibility process was invaluable in pulling all of the project concept information together into one concise document that allowed each party to approve the project without undue delay.” Several aspects of the design and implementation of the 3000m2 facility in Northgate Business Park in Hamilton were important and required particular consideration: PRODUCTION LAYOUT The core function of chocolate production and forming requires both hot and cold processes to be tightly managed from a thermal perspective to View more images of this state of the art facility inside the digital edition. CHOCOLATE PRODUCTION When Waikato Valley Chocolates outgrew its factory premises in Hamilton’s Borman Rd, it didn’t have to look far for expert design fundamentals and construction system advice to suit its specific food production and storage requirements. attain optimum product quality. Apollo designed a robust layout with careful consideration of the production processes and how they interconnected, to maximise the efficiency of the overall facility. TEMPERATURE DIFFERENTIALS The 2000sq metre production area includes several distinct zones including ingredients melting and standardisation, product forming and cooling, and packing, as well as panning which involves the process of coating various ingredients with chocolate. Between the spaces there are significant temperature differentials, which must be managed from a building insulation perspective. Internal Kingspan insulated panels are used extensively, providing excellent insulation characteristics along with high quality food grade hygiene finishes on all surfaces. PRODUCT STORAGE: This is a key factor for Waikato Valley’s business, as production centres around traditional chocolate periods of Christmas and Easter. Apollo developed several scenarios for its client to consider in terms of optimal warehouse size, configuration and expandability. The new 1200sq m finished goods warehouse utilises post-tensioned concrete slabs for increased durability and insulated panel cladding to provide maximum thermal insulation. The PIR Firesafe core in all Kingspan panels also significantly reduces fire spread potential. BUILDING AND EXTERIOR AREA DESIGN The site, building orientation and external yard have all been arranged to provide ample shaded canopy areas at all times of the day for product staging during loading which is specific to operation. A public factory outlet shop is included in the office facility, along with well-appointed open plan office facilities. Staff facilities provide a secure, comfortable space reflecting the needs of the various shifts worked by the 60 staff. “We are thrilled with the result,” Vetsch says. “Our collaboration with Apollo means we now have a plant running at optimum capacity that is purpose-designed and built specifically for our needs.” Visit: www.apolloprojects.co.nz Proud to partner with Waikato Valley Chocolates
FT-Jun17
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