Case Study

Silver Fern Farms

Case Study

Silver Fern Farms

Overall, this project showcases TEG Projects’ ability to deliver complex sustainability solutions within the food and beverage industry, fostering positive environmental and operational impacts for clients like Silver Fern Farms.

This case study examines TEG Projects’ successful collaboration with Silver Fern Farms (SFF) on a decarbonisation project at SFF’s Christchurch plant. The project, co-funded by the New Zealand government, aims to eliminate coal usage and reduce emissions, supporting SFF’s broader sustainability goals.

Client Information

Silver Fern Farms is one of New Zealand’s prominent meat producer, producing 30% of lamb, beef and venison in the country. Their annual sales is $2.5b to over 60 countries from across 14 plants in NZ.

Goal

SFF sought to reduce its reliance on coal and transition towards a more sustainable future. The Christchurch plant’s coal boiler represented a significant source of emissions, contributing to approximately 8% of the co-op’s total coal consumption.

TEG Projects was contracted to manage a project for a comprehensive solution involving:

High-temperature heat pumps: Replacing the coal boiler, these pumps utilise waste heat to preheat hot water for the processing facility. This part of the project was semi funded by EECA GIDI funding.
New engine room: A new engine room housing the heat pumps was constructed within the existing ammonia refrigeration system.
Project management expertise: TEG’s experienced team managed the project from design to commissioning, ensuring minimal disruption to SFF’s operations.

Why TEG Projects

TEG’s proven track record in the food and beverage industry, expertise in project management, refrigeration, and ammonia safety made them ideal partners. Prior collaborations on safety assessments and conveyor/HVAC projects fostered trust and familiarity.

Solution

The new ammonia engine room was a masterpiece of collaboration, drawing on the expertise of leading subject matter experts. TEG facilitated a close working relationship with Silver Fern Farms’ engineering team and Group Energy Manager. This collective knowledge informed the development of detailed specifications and guided a comprehensive tendering process managed by TEG.

The building design was a complex puzzle. It needed to house the necessary plant machinery while adhering to strict ammonia safety regulations, accommodating specific ground conditions, and working within tight space constraints. The project officially kicked off in August 2022 with a groundbreaking ceremony attended by the Prime Minister, Energy Minister, and senior management from EECA and SFF.

To optimise efficiency and meet the project timeline, plant installation progressed in tandem with construction. This allowed for seamless integration of the large equipment and ultimately compressed the project schedule. The automation systems were meticulously designed to adapt to varying plant loads throughout the day and week. This ensures optimal energy recovery and plant operation, whether dealing with low-stage, high-stage, or heat pump functionalities. Additionally, comprehensive ammonia safety systems were integrated to minimise risks for operators, plant operations, and the surrounding community.

Challenges

Operational constraints: Minimising disruption to ongoing production through efficient communication and strategic scheduling.

Design complexity: Balancing plant capacity with stringent safety regulations, ground conditions, and space limitations.

Results

Hazardous materials: Implementing robust ammonia safety measures during design, construction, and operation.

RESULTS:

Reduced coal usage: Expected elimination of over 1500 tonnes of coal annually.
Lower emissions: Significant contribution to SFF’s sustainability goals and national decarbonisation efforts.
Enhanced efficiency: Optimized energy recovery and plant operation.
Improved safety: Integrated ammonia safety systems minimised risks.
Positive employee feedback: Operators appreciate the new plant’s ease of use and enhanced safety features.

Capabilities

Silver Fern Farms