A complex expansion project, involving both greenfield and brownfield development, has successfully delivered a fully automated poultry processing plant in Malaysia. It required high-level integration across buildings, process equipment and utilities, while meeting international food safety standards and optimising energy efficiency.
The project triples capacity at client’s existing plant. Royal HaskoningDHV designed the new facility and provided full engineering, procurement and construction management (EPCM) services.
The development was planned in phases. Supporting utility buildings – including water treatment and rendering – were designed and constructed first. The design of the new primary processing plant included process utilities, such as hygienic air conditioning, and pipework. In final phases, the existing processing plant is being demolished to provide space for administrative and further processing facilities as well as for parking.
State-of-the-art automation requires close coordination for building design
“The processing plant incorporated a completely new automated system so close coordination was vital with our client and key contractors during the design phase,” explained Harco te Lindert, Project Management Director at Royal HaskoningDHV. “A key challenge was the timeline. The plant had to be ready to meet orders for major clients, so we ran phases in parallel and planned construction work in parallel too. This required a strong focus on site safety, and attention to interfacing and accessibility.”
Cold storage designed for maximum efficiency in tropical climate
A massive new cold storage area was constructed which included an automated storage and retrieval racking system. The cold store is 14m high and needs to maintain a temperature of -20°C. Designed as a box within a box, extra insulation in the outer shell helps achieve optimum cooling performance and efficiency in the tropical climate where average external temperatures are around 30°C.