Project Galleries – Food & Beverage
Food Processing Line
Project Details: New production line and all ancillary equipment.
Services Provided: GRG were involved in all stages of the project including capital cost estimating, project scheduling, detailed engineering design and drafting, tendering and procurement, project management.
Packaging and Weighing Equipment
Client: The Smith’s Snackfood Company
Project Details: GRG was involved in all stages of the project including capital cost estimating, capital submission, project scheduling, detailed engineering designs of platform modifications, tendering and procurement, project management including managing the project within budget, installation, commissioning, extensive product trials and testing and project closures.
Water Treatment Plant
Client: The Smith’s Snackfood Company
Project Details: Tertiary water treatment facility capable of recycling 65-75% process trade waste water, saving over 200 million litres per annum.
Services Provided: GRG provided engineering design for the site integration and project management support from conception through to operation.
Food Storage and Distribution Facility
Client: PFD Food Services
Project Details: 10,000m² facility including 2,500m² freezer and 2,500m² dry store.
Services Provided: GRG was involved in all stages of the project including development approval, capital cost estimating, project scheduling, detailed engineering design of technical aspects, tendering and procurement, project management, commissioning and project closure process.
Production Line Relocation
Project Details: GRG Consulting Engineers were engaged to relocate the existing Cruskits Line. After the completion of a purpose built distribution facility, the robotic palletising area became redundant freeing up the required real-estate for the Cruskits line. The building internals were upgraded to food processing standards. An efficient schedule was necessary to minimise the downtime of the line. The decommissioning and re-installation stage was based on a 24 hour, 7 days per week program for a 4 week period.
Services Provided: GRG was involved from the feasibility stage producing alternative layouts, project budget and schedule. Hazard Operability sessions were conducted to identify projects risks prior to the capital submission. GRG provided design, drafting and project management services for the duration of the project.
“Production resumed without compromising supply of the nationally recognised product to the market place. – GRG’s professional engineering services and onsite project management delivered a high-quality relocation on time and within budget.”
Project Details: New snack-food (crackers) roasting line including ovens, custom designed infeed system, seasoning system and ancillary conveyors.
Services Provided: GRG was the engineering and project management service provider in delivering all stages of the project from initial concepts investigation, through to implementation and project closure. This included layout concept drawings and line layout planning, capital cost estimating, capital submission, project planning, detailed engineering designs of access platforms, tendering and procurement, project management and coordination, 3D modelling and integration of equipment from multiple OEM suppliers into a single fully-functional process line, project scheduling, installation, commissioning, product trials and acceptance testing, and project closure.
Project Details: Installation of a complete robotic carton palletiser line, including carton transfer and conveying, automatic palletising, pallet conveying and stretch-wrapping. The palletiser system receives cartons from 3 separate lines simultaneously and palletises in one central cell, streamlining the entire process and removing multiple manual-handling operations.
Services Provided: GRG were responsible for coordinating all stages of the project including the production of specification documents; Capex submission; management of the tendering process; drafting and design to integrate the OEM palletiser system with the existing packaging lines; risk and safety management in collaboration with the client’s personnel; coordination and supervision of installation and commissioning; and project cost management. The project was successfully delivered on-time and within budget.
Site Shutdown and Relocation
Project Details: A multinational Client engaged GRG Consulting Engineers to undertake a facility shutdown and relocate a large portion of the manufacturing equipment to an interstate sister site.
The project required the decommissioning, removal, interstate relocation, installation and recommissioning of the primary production line to be completed inside a 10 day window with building strip out and make good to be completed within 8 weeks from date of closure.
Services Provided: GRG was directly involved with capital expenditure forecasting, scoping, layout development, building reconfiguration, structural design and recertification, system integration and full building make good works across both sites.
Collaboration between the GRG Sydney office and the GRG Melbourne office allowed efficient project handling across the two states with no requirement for interstate travel. GRG Project management systems are integrated across all offices and standardised documentation systems allowed rapid, cost efficient project handover between Engineers.
Macadamias Receivals Area Upgrade
Project Details: GRG was engaged to provide design and project management for an upgrade to the Receivals Area for nut-in-shell macadamias at an existing world-class macadamia processing facility. The design brief was to significantly increase the throughput capacity of the existing Receivals system while maintaining simplicity of operation and minimising implementation cost. By eliminating bottlenecks and increasing equipment size and layout efficiency, the GRG design achieved the target design outcomes with a design throughput increase of 400%. By utilising 3D modelling of complex equipment spatial arrangements, the GRG design successfully integrated new and existing equipment, while providing the client with a comprehensive site model for use in future projects.
Services Provided: GRG completed all design, drafting and project management, from initial concept to final design. This included completing 3D surveys and modelling, developing scopes of work and tender documentation, bulk material properties testing and concept layout development, selection of equipment, contractor engagement, cost estimating and development of issue for construction detail drawings.
Client: Major Snackfood Company
Project Details: Major automation of a brown field packaging hall in order to reduce manual handling/interaction of personnel within a packaging process. Project was based on productivity and required integration with SAP, Wonderware, Scada, Allen Bradley & Siemens software. Final solution consisted of: multiple automated filling stations, high density racking system furnished with aisle cranes and untethered super capacitor carts & multiple 7 axis robots mounted on rail carts. Design of the overall system was such that the only interaction with an operator is to select the various recipe combinations for the final packaging systems and the automated robotic system would then perform all product retrievals and supply in order to complete final packaged product.
Services Provided: GRG was engaged to provide Project Management services from the initial concept, scope development, design layout, equipment selection, planning, budget through to execution, commissioning and final close out of the completed project. The project duration was 5 years from initial concept to project closure.
Mixer Hazardous Areas Rezoning Project
Value: Approx. $450,000
Project Details: Review of Hazardous Area zoning and requirements. Modifications to specific areas of site for appropriate zoning and hazard control..
Services Provided: Conceptual design of alternative bulk handling methods to make a change of zoning to the Hazardous areas associated with the mixers. Zoning argument, report and negotiation with external classifier. Conceptual design elements / selection. Electrical design. Evaluation and selection of alternative diverter valves. Project manage the installation of dust collector / pneumatic conveying systems and commissioning.
Vapour and Dust Extraction
Value: Approx. $175,000
Project Details: Supply / Install powder dust and flavour extraction to the ingredients handling area.
Services Provided: Project manage the installation of a dust collector / ducting system and a vapour extraction system. Project management, contractor supervision and management, installation supervision, hit list development and design reviews of the explosion risks associated with the project.
Macadamia Nut Facility
Project Details: Proposed new facility for receiving, sampling, sorting and drying of macadamia nuts, direct from farm in NIS and NIH form.
Services Provided: Project management services including development of full project budget and project scope coordination. 3D modelling and site layouts for full proposed site. GRG worked closely with the client through the development and consideration of multiple options for site layout, project scope, project implementation staging and greenfield vs brownfield options. Creation of scopes of work and work packages, and coordination of multiple OEMs and vendors for work package tender management on client’s behalf. Collaboration with the client’s town planner for DA submission. (GRG prepared and provided site plans and supporting information as required.)
Project Details: Prepare an Asset Recovery Database for Redundant Facility
Services Provided: GRG prepared an Asset Recovery Database based on the clients finance asset list to ensure all site assets are correctly recorded and organised in parent>child>grandchild format. This enables the client to offer redundant assets for reuse or sale starting at the highest (site) level down to individual items eg. pumps. The requested deliverable was a structured and filterable asset list with identified assets photographed and linked to the database.
Project Details: Structural assessment of the components supporting a new conveyor.
Services Provided: Site visit and measurements of the existing support structure. 3D modelling and 2D drafting utilising Autodesk Inventor. FEA modelling utilising Strand 7.
Platform Structural Assessment
Project Details: Structural assessment of a large existing platform, due to the addition of multiple pieces of infrastructure.
Services Provided: Site visit and measurements of the existing platform. 3D modelling utilising AutoDesk Inventor. FEA modelling utilising Strand 7.
Dispensing Rig Relocation
Project Details: Relocate existing plant to a new location and reconfigure the installation.
Services Provided: Layout creation, project scoping, tender management and project management and commissioning.
Hazardous Area Dust Collector Venting Project
Project Details: Select / Procure / Install Replacement IECEX Fans (4 off ) and duct outside. Reducing dust in areas and increased process safety.
Services Provided: Hazardous areas equipment selection, procurement and integration. Project management.
Arc Flash Hazard Assessment
Project Details: Using Client Single line diagram, inspect and log protection settings, test and log fault loop impedance, note and document non-compliances to AS/NZS3000 or other standards. Calculate arc flash hazard and provide advice on remediation. Produce and install signage.
Services Provided: Arc Flash Assessment, general electrical infrastructure assessment, electrical hazard reduction advice.
Electrical Services for Abattoir
Project Details: New abattoir greenfield development in remote regional location.
Services Provided: RPEQ Electrical Design for Electrical Services, Maximum Demand, Lighting, Emergency and Emergency Exit Lighting, NCC Electrical Requirements.
650kW Solar System Install
Project Details: Client had negotiated with Solar Provider a Solar Power Purchase Agreement for a 650kW Photo Voltaic System to be installed on site.
Services Provided: Contractor Management, Integration into power system, Advice on Solar connection and metering, interpreting and explaining electrical issues, training documentation, support for post installation investigations into voltage fluctuations.
Fresh Pasta Factory Relocation
Project Details: This critical high-profile project included a brownfield factory refurbishment to ‘high care’ standards and the relocation of fresh pasta production and packing lines, bulk ingredients systems and factory services plant from VIC to NSW while maintaining finished product supply continuity.
Services Provided: GRG delivered design, drafting and project management services including design and drafting for factory and production line layouts, building upgrade and building services, structural engineering, scope of works, specifications, tendering management, contractor safety management, scheduling/planning and 24/7 removal and installation supervision across a total project engagement duration of 24 months.
Project Details: GRG was engaged to support and guide a grain storage and packing client in their site expansion plans in regional Victoria. The site receives, stores, cleans, fumigates and packs lentils, chickpeas and maize for export and domestic markets.
Services Provided: GRG completed feasibility stage project scoping, project cost estimation, site layout drafting, scopes of work and requests for quotations, project coordination and project management services.
Honey Bottle Filling and Packing Line
Project Details: Addition of new packaging equipment and modifications to an existing filling and packing line to enable new retail packaging formats for well-established branded honey products.
Services Provided: GRG supported the client with project planning and layouts; including initially conducting onsite measurement and generating layout drawings of the existing line and relevant site areas; and then subsequently developing new layout plans to integrate the new packaging equipment and associated line modifications. GRG also provided support with general planning-phase project management activity including the provision of equipment supplier options and budget cost estimates.
Pet Food Canning Retort Facility
Project Details: New pet food facility for a major food company in NZ
Services Provided: A major, global firm had been engaged for the overall project. GRG was engaged as a sub-consultant to provide technical advisory services and support relating to food-processing and retort systems. GRG’s service provision included process design (FEED), factory and equipment advice, general consulting and drafting; in particular relating to technical process and building services (utilities) for the new pet food retort facility, including steam, condensate, water and compressed air. GRG’s design input fed into the overall building and plant services design by others. GRG also completed preliminary SOWs (RFQ specs) for the conveyors and piping packages.
Machine Safety and Guarding Audit
Project Details: A poultry & fine food producer engaged GRG to complete machine and safety guarding audits on all production and packing equipment in their factory.
Services Provided: GRG completed onsite inspections of all of the machines (60+ machines), then prepared and submitted an AS4024 compliance report complete with risk assessment findings and rectification recommendations.
Mobile Bin Tipper Base Design
Project Details: A fabrication company was tasked to convert a static bin tipper, which was designed to be bolted to the floor, to a mobile bin tipper so it could be moved and used at different areas in the factory. GRG were engaged by the fabricator to design and certify the modifications.
Services Provided: GRG completed design, drafting and certification.
Project Details: GRG supported Sakata rice snacks to plan, manage and supervise the decommissioning and sea freight packing arrangements for a roasting and seasoning line to be removed from their Melbourne factory and freighted overseas for redeployment.
Services Provided: GRG provided project management, planning, site supervision and support.
Strip out of Food Processing Line
Project Details: Strip out of equipment from within an existing operational site in preparation for new equipment installation. Some equipment to be packed for export. The processing line to be removed was functional and was to be retained and reused elsewhere so the removal works required careful planning to minimise damage, while also minimising disruption to the rest of site which continued to operate. The work involved cutting a large penetration into an existing wall to create a suitable forklift access door and egress pathway.
Services Provided: Planning, estimation of cost, organising contractors, onsite management of works and contractor safety, interacting with plant personnel to minimise disruptions.
Other Recent Food Processing Projects
- Oil Heating, Filtration, Transfer, Measurement and Storage
- Salt and Seasoning Equipment
- Packaging, Weighing, Bag Makers and Conveying Equipment
- Fryer Systems
- Oven Systems
- Metal Detectors, Checkweighers, X-ray, Seal Checkers, Optical Sorters
- Control Systems
- Platforms, Structures and Lifting Devices