FDBusiness.com

In three years Glanbia Ingredients Ireland’s Belview facility has literally come from a green field in County Kilkenny to a world class 24,000 sq m dairy plant built to infant formula standard. The largest single capital investment (€180 million) in Ireland by an indigenous Irish company, Belview was designed and project managed by PM Group to process up to three million litres of milk per day into a range of specialised milk powders and nutritional ingredients to meet the demands of multi-nationals in infant formula and other industries around the world.

PM Group began the project in 2011 initially working on the concept design and site selection and continuing through planning applications, IPPC licence application, full engineering design, procurement, construction management, commissioning and start up assistance to deliver first milk in December 2014.

Projects of this size inevitably pose many challenges around design, safety co-ordination, scheduling, cost control and quality.

Substantial Design Co-ordination

This type of complex process driven design project required substantial design co-ordination between the various engineering disciplines and the process (GEA) and utility contractors. The main feature of the site is a tower in excess of 40 metres, housing two large spray dryers. PM Group used the latest 3D modelling design tools to design a fully integrated facility.

A fast track Construction Management approach was implemented starting with an enabling works contractor appointed in May 2013. Multiple other trade contractor appointments followed, culminating in the plant being ready to receive first milk in December 2014 on schedule. The construction management approach combined with strong cost management throughout the design and build ensured the facility was delivered on time and within budget.

Construction Safety

According to John Harte, PM Group’s Project Manager: “Construction safety was paramount at all times with a peak of 785 workers on site and over 1.5 million construction manhours executed in total. In excess of three thousand people received safety induction training on site during the course of the project.”

GMP is a particular focus for a facility of this size which featured 300,000 cu m of excavations, 40,000 tonnes of concrete, 35,000m of pipe, 536km of cable, 10,000 sq m of ducting and 1,180 instruments and all installed to the highest standards.

“The Glanbia Ingredients Ireland Belview project had quite an impact on our dedicated food engineering team. We have extensive experience in the design and build of major dairy and infant nutrition projects in Europe and Asia. But to complete such a world class project close to our HQ was a fantastic experience,” says Tom Waters, Food Sector Director at PM Group.

For further information visit PM Group at www.pmgroup-global.com.