food and beverage - chinagoabroad · 11 food and beverage food and beverage capability amec has...

Food and beverageBioprocess & Controlled Environments

Senior ManagementJoe GangiManaging Director Bioprocess & Controlled Environments, Australia and South East Asia

Darren GreenTechnical Director Bioprocess & Controlled Environments, Australia and South East Asia

Frederic JeunetGeneral Manager Bioprocess & Controlled Environments, Australia

Nenad FirezBusiness Development Manager, Bioprocess & Controlled Environments, Australia

Tel: +61 (0) 400 495 885 Email: [email protected]

ContentsCompany overview 1

Beyond Zero 2

Services 3

Project delivery 3

Engineering 5

Architecture 7

Environmentally sustainable design services 8

Procurement and construction management 9

Commissioning services 10

Operation support 10

Food and beverage capability 11

Relevant experience 13

Clients 13

Water Treatment / Bottling Plant 14

UHT Filling Room and System Upgrade 15

Beer Processing Facility 16

Other selected project history 17

Company overview

1 Food and beverage

AMEC is a focused supplier of consultancy, engineering and project management services to its customers in the world’s oil and gas, minerals and metals, clean energy, environment and infrastructure markets. AMEC designs, delivers and maintains strategic and complex assets for its customers.

AMEC’s businesses employ over 29,000 people in more than 40 countries globally. AMEC shares are traded on the London Stock Exchange. The company has a strong reputation for operational excellence, and combining global excellence with local delivery.

In 2011, AMEC and Zektin Engineering combined strengths to improve delivery for our customers by offering combined expertise, wider global coverage and increased scale within the bioprocess and controlled environment sectors within Australia and South East Asia.

AMEC’s Bioprocess & Controlled Environments business operates from Australia and China and services a wide variety of related industries:

Bioprocess

• Biotechnology and pharmaceutical

• Laboratories and research facilities

• Food and beverage

• Biofuels

Renewables

• Biomass / Bioenergy

• Solar

• Wind

Industrial / Commercial

• Advanced manufacturing / Heavy industrial

• Waste treatment and emissions control

• Energy efficiency and optimisation

Government Services / Defence.

AMEC’s global locations

AMEC’s Australian locations

AMEC’s project locations

AMEC’s vision is to achieve sustainable, world class Health, Safety, Security and Environmental (HSSE) performance excellence throughout our global operations.

The AMEC Beyond Zero program aims to create an HSSE culture where strong leadership, personal responsibility and an unyielding commitment to excellence are cornerstones of how we conduct our business. We consistently take HSSE performance beyond the work place and out into the wider community.

Engagement at various levels within the organisation provides an opportunity to influence safety behaviour and create a culture of HSSE commitment greater than self-interest. AMEC has developed engagement tools to support this process, taking our HSSE performance ‘Beyond Zero’.

Beyond Zero

I believe real leadership can only be demonstrated by setting personal standards that capture the hearts and minds of our people, thereby encouraging the right attitudes and behaviours throughout the organisation.’’Neil Bruce, Chief Operating Officer AMEC Natural Resources

Food and beverage 2

ServicesProject delivery

AMEC’s project delivery is based on a proven gate system that ensures the deliverables are appropriate to the relevant project phase.

This system is well aligned with our clients’ requirements for funding approvals and improves our clients’ risk management profile due to our experience with and understanding of all phases of asset life cycles. This knowledge enables our clients to achieve their business objectives by confidently making decisions that provide optimal solutions for profit and sustainability.

3 Food and beverage

AMEC is a focused supplier of high value consultancy, engineering and architectural services to the world’s Controlled Environment and Bioprocess industries.”

Food and beverage 4

Engineering

AMEC offers a multi-disciplined engineering design team, which includes Mechanical, Chemical, Process, Electrical, Instrumentation and Automation engineers, and associated drafting support.

Our engineers are skilled in providing design in compliance with a wide range of regulatory bodies and codes, relevant to our industries of specialisation.

The knowledge base gained from our widely varying range of speciality projects brings to our clients a source of design solutions that provide innovative and cost effective outcomes.

Our aim is to fully understand our clients’ scope, cost, time and quality requirements, and ensure that our assigned personnel have the experience and resources necessary to exceed our clients’ expectations. Our focus is to deliver a fully co-ordinated, process driven design with strong emphasis on compliance and safety.

AMEC’s scope of services span the entire asset life cycle from Phase 1 (Feasibility Study) through to Phase 5 (Operation).

Phase 1

Feasibility study

� User brief � Concept options � Feasibility analysis � Modelling � Execution strategy � Value assessment.

Phase 2

Concept design

� Project verification plan

� User requirements specification

� Concept design documentation

� Design criteria � Site selection � Cost planning � HAZOP 1.

Phase 3

Schematic Design

� Functional specification

� Schematic design documentation

� Design basis � Planning documentation

� Cost estimating � HAZOP 2 � Risk assessments / safety reviews.

Phase 4

Detailed design / tender / execution

� Design specification � Design qualification � Detailed design documentation

� Authorities approval � Cost estimating � HAZOP 3 � Risk assessments / safety reviews

� Tender evaluation / review � Construction supervision / assistance

� FAT / SAT � Commissioning � Installation verification / operational verification / performance verification.

Phase 5

Operations

� Operational assistance

� Process optimisation

� SOP’s � O&M manuals � Value assessment.

Engineering delivery model

5 Food and beverage

We utilise best industry practices in all areas of our business, providing the following service range to our clients:

Project management (incl. capital cost estimation, cost control and planning)

Field development strategies and planning

Feasibility and conceptual studies

Front end engineering design (FEED)

Process / production modelling

Project risk analysis

HAZOP Studies, SIL reviews & safety management studies

Plant layout

Detailed design (2D or 3D modelling)

EPCM services.

Food and beverage 6

7 Food and beverage

Architecture

AMEC is committed to delivering truly exceptional professional design services which are tailored to the specifics of our clients and their projects.

We deliver successful projects through extensive client collaboration from inception to occupation, co-ordinated multi-disciplined integrated design teams, and the implementation of comprehensive consultancy processes.

AMEC’s architectural design professionals approach projects with careful analysis, creative and technical skill, innovation, and proven design experience, ensuring project information is continually shared, coordinated and updated across our multi-disciplined teams.

Phase 1

Predesign

� Brief preparation � Feasibility studies � Site analysis � Space analysis � Functional relationship diagrams

� Flow diagrams � Block planning � Masterplan.

Phase 2

Schematic design

� Site layout � Schematic design � Site development options

� Data sheets.

Phase 3

Detailed Design

� Detailed design � Town planning application

� Outline schedules of materials, finishes, colours & fixtures

� 3D modelling � 3D animations.

Phase 4

Contract documentation / tender / contract

administration

� Working drawings � Specification � Schedule of materials / finishes / colours

� Building permit application � Tender process & negotiations

� Contract administration.

Phase 5

Post contract

� Defects liability period

� As-built documentation

� Post occupancy evaluation.

Architectural delivery model

Services include the following:

�Design management, Design co-ordination

�Strategic facility planning, Master planning

�Feasibility studies, Brief formulation

�Schematic design

�Developed design

�Contract documentation

�Contract administration

�Post contract services

�Post occupancy evaluation

�3D animation

�Interior design.

Food and beverage 8

Environmentally sustainable design services

AMEC offers a multi-disciplined and integrated approach to achieving ESD principles and Green Star Ratings to projects.

Sustainability is the base principle in our approach to delivery of projects. With our accredited GBCA Green Star Professionals, which include our Architectural, Process, Mechanical and Electrical disciplines, we deliver successful Green Star projects through extensive design team and client collaboration.

AMEC utilises best sustainable design practices in all areas of our business, providing the following service range to our clients:

�Life cycle cost analysis

�Energy efficient HVAC and building services systems using innovative design solutions

�Ecologically sustainable architectural design

�Water recycling and reuse solutions

�Integration of renewable energy solutions

�Waste treatment and waste products reuse

�Emissions control, Heat recovery systems

9 Food and beverage

Procurement and construction management

AMEC offers the following procurement and construction management services:

Procurement management

�Identification and approval of suitable contractors

�Development of tender packages and contract conditions

�Assessment and analysis of tender submissions

�Recommendation of tender offers

�Preparation of orders

�Expediting

�Assessment and approval of vendor data

�Inspections

�FAT / SAT.

These tasks can be carried out using AMEC’s proven systems or tailored to our clients’ preferred or existing systems:

Construction management

Construction management can be executed on behalf of our clients, or individual discipline support can also be provided where appropriate and can be in conjunction with client representatives or other service providers.

�Assistance during construction

�Site supervision

�Site management

�Contract management.

Commissioning services Operation support

AMEC is widely experienced in the start up and commissioning of complex technical facilities and process systems.

Our inherent understanding of the way things work brings a thorough approach to commissioning, with the use of job specific methods and procedures, delivering safe and incident free start-up. This provides a high degree of confidence for plant operation and validation in regulatory controlled project environments.

Our commissioning services experience includes:

�Preparation of inspection and test plans

�Preparation of commissioning plans

�Preparation of commissioning procedures

�Commissioning management and direct supervision

�Plant start up and performance testing

�Commissioning documentation compilation

�Compliance documentation.

AMEC is experienced in plant operation and development of documentation. for operations and ongoing compliance.

�Development of standard operating procedures

�Development of maintenance procedures

�Operator training

�Operations advice

�Operational optimisation assessments

�De-bottlenecking studies

�Hazard identification and rectification.

Food and beverage 10

11 Food and beverage

Food and beverage capabilityAMEC has developed significant expertise in the Food and Beverage Industry, where we have delivered projects in areas such as dairy, beverages (water, beer, wine and soft drinks), dry foods, bakeries, flavours and consumer foods. Our process engineers get involved in the early stages of projects in order to ensure that good manufacturing practices and food safety standards are implemented throughout the design and project delivery.

AMEC’s core competencies in the process, process services (including utilities), architectural and building services design include:

�Architectural and building services (HVAC, electrical, instrumentation & controls, hydraulics)

�Waste treatment (liquid waste, chemical waste, toxic waste)

�CIP Design

�SIP design

�Sterile filling

�Powders blending and dispensing

�Liquids formulation and filling

�Raw materials handling and dispensing

�Primary and secondary packaging

�Decontamination and fumigation

�Dust control

�Hazardous and flammable goods stores

�Cleanroom environment.

AMEC has designed GMP Facilities processing plants and facilities in compliance with FSANZ (Food Standards Australia and New Zealand), BRC (British Retail Consortium), Food Safety Standards, and the US FDA (Food and Drug Administration).


Our expertise and services are available for all stages of your project; from concept development through to operational support.’’


Relevant experienceClients

�3 Ravens

�Brickwood Holdings Pty Ltd

�Coca Cola

�Bonlac Foods Ltd (now Fonterra Foods)

�International Flavors and Fragrances (IFF)

�National Foods Ltd, Cobden, Victoria

�Pactum Australia

�Snowbrands

�Tooheys.


Water Treatment / Bottling Plant | Brickwood Holdings Pty Ltd

Phase 1

Feasibility study

Phase 2

Concept design

Phase 3

Schematic Design

Phase 4


Phase 5

Operations

Phases executed by AMEC

The project objective was to build a state of the art, fully automated water bottling plant. The project target was to fill bottles ranging from 250ml to 4L with either ozonated or non-ozonated, but sterilised spring water.

Other key requirements included the ability to supply water from one of the three storage silos whilst loading and/or cleaning another as well as protection against overpressure of the Ultra Filtration (UF) membranes. Compliance to best practice sanitary design and automated cleaning and sanitisation were also mandatory requirements.

Key Functional Areas

�Water storage silos (outdoor)

�Waste tank (outdoor)

�Tanker unloading facility (outdoor)

�Water reticulation system (indoor)

�Water treatment system (indoor)

�Clean in Place (CIP) and sanitisation system (indoor)

�Filling and packing equipment (indoor)

�Robotic packaging equipment (indoor).

AMEC Services

�Design management

�Construction supervision

�Process engineering design

�Electrical engineering design

�Instrumentation engineering design

�PLC program specification

�Commissioning

�Qualification assistance


�O&M manual preparation

Project Outcomes

The end result offered a water storage and reticulation system capable of feeding a bottling plant with 19,000L per hour of purified drinking water. The water processing plant also provided the ability to vary the flowrate depending on bottle size being filled. Differential pressure monitoring and plant shut down ensured that the UF membranes remained protected.

A significant reduction in capital equipment cost was achieved by integrating the bottling machine’s CIP system with the reticulation plant. This meant that one CIP system was utilised to clean all major equipment items in the facility. Plant downtime was minimised by utilising mix proof technology to create safe process interchanges. This enabled simultaneous bottling plant supply, silo loading and CIP/santisation.


UHT filling room and fumigation system upgrade | National Foods Ltd

Phase 1

Feasibility study

Phase 2

Concept design

Phase 3

Schematic Design

Phase 4


Phase 5

Operations


The UHT filling process uses H2O2 in both the bottle preparation and foil areas of the filling line for sterilisation purposes. The plant was experiencing considerable leakage through both the change room and through the exit from the seal and cap area into adjacent areas. It was also found that the fume extraction unit was incapable of removing sufficient levels of H2O2 from the filling room creating risk to operators.

The key objective was to introduce an innovative solution which eliminated the need to wear respiratory equipment within the facility and also eliminate leakage into adjacent areas.


�UHT filling suite

�Personnel change room

�Plant space

�Structural mezzanine platform

�Roof space support structure

�Packaging hall

AMEC Services

�Project management

�Design management

�Mechanical (HVAC) engineering design

�Structural engineering design

�Electrical engineering design

�SCADA system upgrade

�Site supervision

�Commissioning

�Qualification assistance


�O&M manual preparation

Project Outcomes

An innovative solution involved the design and installation of a dedicated AHU responsible for exhausting the H2O2 from the bottling line such that negligible levels were detected in the filling suite, change room and adjacent areas.

The key feature was the design of the capture hoods around the machine. The outcome of the engineering solution was the total removal of risk from the filling suite and adjacent areas resulting in the elimination of the use of respiratory equipment. Detection equipment was also introduced as well as GMP principles in and around the change room to prevent ingress of contamination and leakage of gas.

The solution was introduced with minimal downtime to the plant and efficiently commissioned by the designers.


Beer processing facility | Tooheys

Phase 3

Schematic Design

Phase 4



Tooheys required a new bright beer processing facility and upgrades to associated beer production, service utilities, canning and bottling equipment.The new facility is used for processing premium beers such as Heineken for the Australian market.

The key objectives which the facility had to deliver were, improved efficiency and high quality production, reduced production costs through improved energy and water efficiency, increased labour efficiency and reduced product loss, resource consumption, waste and pollution, as well as compliance with state and commonwealth environmental policies.


�Beer processing

�MCC room (fire rated)

�Control room (fire rated)

�Satellite test lab

�Admin offices

�Staff amenities

�Disabled WC

�Stores

�Plant & maintenance rooms

AMEC Services

�Architectural design

�Mechanical engineering design

�Electrical & data engineering design

Project Outcomes

Robust, functional and cost effective facility successfully connected to existing beer production building and sited / accommodated amongst other existing buildings, storage tanks and site utility services.

Operational efficiencies achieved through integrated design approach with regards to building services, production services (diverted and directed into facility via pipe rack), production equipment and architecture. Careful attention to architectural construction detailing and methods for wet / wash down areas, anti-vibration plinths supporting specialist equipment, access floors and 2hr fire ratings to various areas.

Efficient and high quality beer production ensuring competitiveness and long term viability in the Australian market.


Other selected project history

Client Description of services

Pactum Australia, UHT Milk Processing Facility, Victoria

AMEC provided a feasibility study for a new UHT Milk Processing Facility, including the engineering and building assessment of an existing warehouse facility in Shepparton. This included liaison with local council on service connection, development of concept layouts, development of site and facility flows, interpretation of process requirements and cost estimation. Project Value approx $40M.

Snowbrands, Victoria AMEC was engaged as the principal consultant for architectural, mechanical and electrical design services from schematic design to tender for additions and alterations to their powdered milk manufacturing plant. AMEC produced design and documentation solutions to prevent possible ingress of bacteria to the manufacturing and packaging facility, alterations to the entry points and office as well as design an external workshop for the facility.

Coca Cola, Liquid Storage Facility, South Australia

The liquid storage for 460,000 litres of potable (vodka, Rum, etc) alcohol at the premixed drinks facility. AMEC was responsible for the hazardous area zoning as well as the dangerous goods storage and handling recommendations including fire protection and suppression systems. A similar role, but at smaller scale, was performed at the Brisbane facility.

3 Ravens Microbrewery, Victoria

AMEC provided full design and project management for a 100 hectalitre microbrewery complete with bright beer plant, microfiltration and fermentation hall. Facility was designed with semi automated CIP facilities and full temperature process control. The facility included a conditioning cold room operating at 4 deg C, a hot room for yeast incubation at 25 deg C and a conditioning room at 20 deg C (Project value AUD $1.5M).

International Flavors and Fragrances (IFF), Victoria

AMEC was engaged as project managers and process designers for the upgrade of the process areas of this plant at Dandenong. The facility processes flammable liquids and powders.

Hooker Cockram Projects, New South Wales

AMEC completed a project for Hooker Cockram Projects at Tooheys Brewery, NSW. The project comprised of an extension to the bright beer cellar involving pilot QA lab, control room and production offices. Services included mechanical, electrical and architectural design.

National Foods Ltd, Cobden, Victoria

AMEC completed the upgrade of the Sterile Filling Room HVAC and extraction systems at the UHT plant at Cobden.



Bonlac Foods Ltd (now Fonterra Foods) Cream Blending Project, Victoria

Complete project management, detailed design and documentation, construction supervision and management, procurement management, commissioning, IQ / OQ, production handover and training. , (Project Value AUD $750K)

Bonlac Foods Ltd (now Fonterra Foods) Triple “M” Cream plant, Victoria

User requirement specification, Preliminary design, Project cost estimations, Development of tender documentation, Project engineering and construction supervision, Commissioning. (Project Value AUD $2M)

Bonlac Foods Ltd (now Fonterra Foods) Ricotta Make Plant, Victoria

Project and Construction Management, Preliminary and Detailed Design including Documentation, Functional Specifications, Instrumentation and Control Design, Project Engineering and Construction Supervision, Commissioning. (Project Value AUD 750K)

Bonlac Foods Ltd (now Fonterra Foods) Cheese Plant Upgrade, Victoria

Project and Construction Management, Preliminary and Detailed Design including Documentation, Project Engineering and Construction Supervision, Commissioning.

Projects:

�Cheese Whey Fines Recovery (Project Value AUD $60K)

�Mozzarella Pear Moulding (Project Value AUD $15K)

�Cream Pasteurization Cooler (Project Value AUD $50K)

�Ricotta Whet Recovery (Project Value AUD $120K)

Bonlac Foods Ltd (now Fonterra Foods) Milk and Butter Plant, Victoria

Construction Management, Preliminary and Detailed Design including Documentation, Project Engineering and Construction Supervision, Commissioning

Projects:

�Cream Concentrator Installation (Project Value AUD $500K)

�Lactose Permeate Upgrade (Project Value AUD $100K)

�Milk Receival Silo Installation (Project Value AUD $260K)

�Print Butter Machine Relocation (Project Value AUD $300K)



Bonlac Foods Ltd (now Fonterra Foods) Cheese Plant Upgrade, South Melbourne

Project and Construction Management, Preliminary and Detailed Design including Documentation, Project Engineering and Construction Supervision, Commissioning

Projects:

�2 Deg.C Coldroom (Project Value AUD $35K)

�Film Room (Project Value AUD $125K)

�Hot Water Plant Installation (Project Value AUD $130K)

�Robotic Decartoning Plant (Project Value AUD $750K)

�Cookroom Upgrade (Project Value AUD $130K)

�CIP System Upgrade (Project Value AUD $50K)

�Casting Room Upgrade (Project Value AUD $250K)

� IWS Cheese Infeed Line (Project Value AUD $560K)

�Cheese Waxing Baths (Project Value AUD $50K)

Bonlac Foods Ltd (now Fonterra Foods) Milk Plant Upgrade, Toora, Victoria

Project and Construction Management, Preliminary and Detailed Design including Documentation, Project Engineering and Construction Supervision, Commissioning

Projects:

�Lactose Powder Handling System (Project Value AUD $500K)

�Chilled Water Upgrade (Project Value AUD $250K)

�Milk Standardisation (Project Value AUD $125K)

Bonlac Foods Ltd (now Fonterra Foods) Cheese Plant Upgrade, Drouin, Victoria

Feasibility Study, Preliminary Design, Project Costing, Project Proposal, Tender Preparation

Projects:

�Whey Separator Upgrade (Project Value AUD $125K)

�10gm Tub Butter Fill (Project Value AUD $2.1M)

�Plant HVAC Upgrade (Project Value AUD $500K)

�Effluent Plant Upgrade (Project Value AUD $120K)

�MFD Air Conditioning Upgrade (Project Value AUD $155K)

�Milk Receival Area (Project Value AUD $100K)

�Concentrate Heater (Project Value AUD $140K)

�Niro Building HVAC (Project Value AUD $200K)

�Refrigeration Plant Upgrade (Project Value AUD $360K)

�Buttersalt Dosing System (Project Value AUD $260K)

�Palletiser Installation (Project Value AUD $300K)

Find out more at amec.com

Please contact Nenad Firez

Business Development Manager, Australia

Tel: +61 (0) 400 495 885 Email: [email protected]

Melbourne AMEC, Level 15, 300 La Trobe Street Melbourne, Victoria 3000 Tel: +61 3 8480 1000 Fax: +61 3 8480 1055

Sydney AMEC, Level 10, 67 Albert Avenue Chatswood, New South Wales 2067 Tel: +61 (0) 410 083 833

Brisbane AMEC, Level 4, 144 Edward Street Brisbane, Queensland 4000 Tel: +61 7 3013 7700 Fax: +61 7 3013 7755

Perth AMEC, Level 7, 197 St Georges Terrace Perth, Western Australia 6000 Tel: +61 8 9347 4777 Fax: +61 8 9347 4747

Jakarta AMEC Berca Indonesia, CCM Building 4th Floor JI Cikini Raya no. 95 Jakarta 10330 Indonesia Tel: +62 21 315 9040 Fax: +62 21 314 2740

Kuala Lumpur

AMEC Larastia, Suite 10.2 Level 10 East Wing, Rohas Perkasa No. 9 Jalan P. Ramlee 50250 Kuala Lumpur, Malaysia

Tel: +60 3 2162 1230 Fax: +60 3 2163 1231

Muntinlupa City AMEC, Insular Life Corporate Centera Level 22 Tower 1, Corporate Corner Commerce Avenue, Filinvest Corporate City, Alabang Muntinlupa City, Philippines 1780

Tel: +632 7711576 to 78 Fax: +632 7711532

Shanghai AMEC, Unit 3007-3012 Shanghai Information Tower, 211 Century Avenue, Pudong New District, Shanghai 200120 China

Tel: +86 21 3861 5599 Fax: +86 21 5877 0248

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