market brochures - manufacturing

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Manufacturers look to continually improve their productivity through innovation, efficiency gains, reduced wastage, better utilisation of human capital, and better management of high cost inputs, such as energy.

Our expertise

Aurecon has a strong track record in

supporting manufacturing clients to improve

project outcomes by providing innovative

manufacturing solutions that address

efficiency gains, reduce waste, better utilise

human capital and reduce high cost inputs

such as energy.

Our track record demonstrates Aurecon’s

ability to deliver environmentally sustainable,

cost-effective solutions that span the entire

life cycle of manufacturing projects.

With a strong client focus, Aurecon integrates

and aligns our experienced teams with our

clients’ expectations to deliver best practice

for project outcomes across safety, risk,

quality, budget and schedule.

Health and Safety

Health & Safety comes first in everything we

do and is a core value for Aurecon. We foster

this by appointing experienced teams who

combine a deep understanding of the

management of Health & Safety with that

of our clients.

We integrate and align our teams with our

clients to deliver best practice project

outcomes across safety, risk, quality, budget

and schedule.

Innovative specialties

Vacuum Salt Plant Upgrade New Zealand

Agribusiness Ranging from irrigation through to bulk material handling and

storage and refining of products, Aurecon’s broad

agribusiness experience encompasses the wide range of

services required to manage the production, storage and

processing of agricultural materials across sugar, grain, salt,

fish, meat, wool, fertiliser and leather products.

Automotive Our support for the automotive industry has involved projects

for major automotive assembly facilities, as well as for

suppliers to the automotive industry and related retail outlets.

Our expertise incorporates the design and construction

management of automotive facilities including planning, civil,

structural and electrical engineering, heating, ventilation and

air conditioning (HVAC) and project management.


NBL Mbarara Brewery Uganda

Cement With more than 40 years of experience in the cement

industry, Aurecon has earned a strong reputation as a

leader in design technology relating to raw materials

handling and product storage. We are at the forefront of

silo design, with particular experience in post-tensioned

concrete, reinforced concrete and steel silos.

Food and beverage Aurecon’s food and beverage experience spans the dairy,

bread, wine, beer and non-alcoholic beverages subsectors,

providing process, mechanical, civil, structural, electrical

and automation services for plant upgrades and greenfield

designs. Our design and construction support for the global

beverage industry is based on our understanding of the

operational requirements for a beverage facility and our

knowledge of the packaging equipment used provides an

important interface between equipment vendors and client.


Raw material salt pile supplying the Vacuum

Salt Plant at Dominion Salt, Mount Maunganui

New Zealand

Metals and minerals We have a strong reputation in the engineering,

documentation and project management of major

equipment installation in heavy industrial projects, both

within operational plants and on greenfield sites. Aurecon’s

capabilities span the entire life cycle for metal and mineral

products and includes steel, aluminium, nickel, lead and

zinc metal products as well as gypsum, sands, limestone

and bentonite and other mineral products.

Wood, pulp and fibre Covering a wide range of industries using or processing

forest products, Aurecon’s experience spans chemical and

thermomechanical pulp, fibre board manufacturing, tissue

manufacturing, wood drying and biomass fuel.


Siam Bentonite Expansion Project Thailand

Oil and gas From downstream fuel storage and distribution to planning,

environmental and infrastructure support for major oil and

gas projects, Aurecon’s extensive experience encompasses

a wide range of hydrocarbon products including aviation

fuels, heavy fuel oils, diesel, motor spirits, grease, ethanol,

biodiesel, lubricating oil, petrol additives, liquid condensate,

bitumen, natural gas and liquefied petroleum gas (LPG).

We undertake work on pipelines as well as gas networks

and have expertise in risk and safety engineering.

Our support for major projects includes environmental

assessments and approvals, marine structures, roads,

airports, power supplies, warehouses and storage

facilities, office facilities, accommodation, communications

and training.

A tailored services mix Aurecon’s multidisciplinary services span the entire manufacturing life cycle,

from concept through to implementation and asset management.

A tailored services mix

Siam Bentonite Expansion Project Thailand

Client AMCOL International (Thailand) Limited

The client needed to substantially increase their bentonite

production capacity and range of products at their facility.

Aurecon was appointed to deliver the detailed process,

mechanical, electrical, civil and structural design for the

processing facilities, as well as site development,

services, utilities, roads and administration buildings.

Aurecon successfully delivered all project outcomes,

including development of plan layouts that met all process

requirements, maximised the use of gravity feed, provided

for future expansion and fitted within the footprint provided

for the plant at the time of initial project planning.

Our work optimised the blending process to better match

the weighing of constituents and batch mixing process

with the required overall plant production capacity,

provided for effective and safe plant access for

operational and maintenance requirements and

addressed the explosive dust issues in accordance with

the requirements of the National Fire Protection

Association (NFPA 68).

Our global success stories

NBL Mbarara Brewery Uganda

Client Nile Breweries Limited (NBL)

NBL, Uganda’s largest brewer, appointed Aurecon as the

civil and structural consultants for a new greenfield

brewery in Mbarara. Throughout the design phase, the

key objective was a design which would allow NBL to

construct the brewery economically and to strict

quality standards.

The design optimisation process started at project

inception, establishing an integrated site layout that

has since been used as a model for other breweries.

NBL also had additional, strict requirements regarding

the design of the brewery’s external environment and

industrial emissions.

Aurecon has subsequently been appointed for full

engineering, procurement and construction management

(EPCM) services for the project.

This project won Best International Project at the CESA

Aon Engineering Excellence Awards in 2013.


Dulux Gracefield Site Redevelopment New Zealand

Client Dulux Group New Zealand

Dulux Group New Zealand is a leading manufacturer and

marketer of premium branded decorative paints, texture

coatings and woodcare products. In 2009, Dulux moved

to increase water-based paint production capability and

eliminate production of solvent based paint at the

Gracefield manufacturing and warehousing facility, rather

than pursue an expensive greenfield development.

Completed in six stages, Dulux’s Gracefield Site

Redevelopment in Wellington re-lifed the 70 year-old

plant, creating sweeping changes by eliminating solvent

based paint and substantially increasing water-based

paint production capabilities. Aurecon provided all

consulting services, including process engineering,

structural, building services, civil, geotechnical, and

survey for the upgrade of all manufacturing facilities and

infrastructure at the plant. The project team not only

enabled Dulux to produce paint during the redevelopment,

but also reduced planned production shutdowns to only

20 working days in nearly two years of construction.


Coca Cola Plant Namibia

Client Namibia Beverages

Aurecon was appointed to design a 3 350 square meter

steel structure for an urgently required additional

production area, new syrup room, crown store, HP

compressor room, a transformer room, production hall

and warehousing facility, as well as an enlargement of

their existing warehouse.

Aurecon prepared design and tender documents for

three contracts, all of which assisted in shortening the

design and construction phase as much as possible.

The three tenders included an earthworks tender which

was started within three weeks of project initiation, a

separate building contract and a steel structure supply

and erection contract.

Most of the plant is constructed on approximately two

metres of uncontrolled filling material, which forced the

contractor to excavate each column footing to about 2.5

metres deep. In situ material was then compacted and the

excavation backfilled with soilcrete up to approximately

1.2 metres from final floor level.


Vacuum Salt Plant Upgrade New Zealand

Client Dominion Salt

Aurecon, in association with the client and equipment

suppliers, was tasked with developing the project concept

and detailed design for an expansion to increase salt

production by 50 per cent. Aurecon prepared and project

managed the equipment supply and installation contracts

for the main evaporation plant and new steam turbine

from construction through to plant commissioning.

A major challenge was to minimise capital cost while

significantly improving plant operating efficiency. The

solution was to expand the existing evaporator into a new

five effect evaporator.

Aurecon also developed a design that provides for the

simultaneous manufacture of pharmaceutical and food

grade salts, eliminating the need for separate batched

campaigns and associated plant downtime.

This project won an innovation award at the Energy

Efficiency and Conservation Authority Awards 2012.


Queensland Alumina Ltd (QAL) High Voltage Reticulation Upgrade Australia

Client QAL

QAL’s Gladstone refinery, operating since 1967, is one of

the largest alumina refineries worldwide. The refinery’s 11

kV distribution network is one of Queensland’s largest and

most complex for an industrial plant. This project involved

converting the ageing network to a new distribution

arrangement aligned with QAL’s needs for safety in

operation, security of supply, and scope for future

expansion. Aurecon undertook the initial options analysis

and feasibility studies and delivered the definitive

engineering phase, project implementation and successful

handover. Aurecon worked closely with QAL to develop

the preferred solution, which included a simplified 11 kV

network arrangement. New 11 kV switchboards enabled

the pairing of QAL’s incoming transformers to address

fault levels and security issues, and interconnection with

QAL’s on-site generation. The main Substation 42 was

also linked to the newer Substation 42W. The

implementation of this project has provided QAL with a

safer and more robust 11 kV distribution system and

considerably reduced the system’s risk profile.


Hautapu Lactose Evaporator Project New Zealand Client Fonterra

Aurecon worked with Fonterra to provide an innovative

solution to improve the manufacture of lactose, a major

component of the milk processed in the dairy industry and

an ingredient in the production of many processed foods.

A new evaporator and lactose concentrate

load-in facilities were installed at the Hautapu Dairy

factory site in Waikato, New Zealand. The new evaporator

provides extended product run times, improved product

yield, reduced water and chemical requirements for

cleaning, lower product losses and results in less water

being generated than existing evaporator options.

The project has recovered what would have been

a low value by-product and produced a valuable

trading commodity.

Award-winning innovation Gold Award ACENZ Innovate NZ Awards of Excellence 2010

Registered office, Singapore

152 Beach Road #22-02

Gateway East

Singapore 189721

T +65 6256 6188

E [email protected]

Registered office

Australia, Melbourne

Aurecon Centre

Level 8, 850 Collins Street

Docklands VIC 3008

Australia

T +61 3 9975 3000

E [email protected]

Registered office, South Africa

Tshwane

Aurecon Centre

Lynnwood Bridge Office Park

4 Daventry Street

Lynnwood Manor 0081

South Africa

T +27 12 427 2000

E [email protected]

market brochures - manufacturing

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