Optimising poultry processing: Hazeldenes enhanced capacity and efficiency

The project successfully delivered a 50% capacity increase in a world class processing facility, in addition to substantial cost reductions through strategic application of automation and cold chain excellence improvements.

Transforming processing capacity through strategic optimisation

Hazeldenes engaged NIRAS to optimise their existing secondary processing facility and increase throughput per week. The multi-million dollar project encompassed complete site-wide master planning, and initial design through to commissioning of the secondary processing facility.

NIRAS delivered comprehensive services including master planning, conceptual and detailed design, tendering and procurement coordination, and construction phase management. The scope included secondary processing optimisation, cold chain excellence, and logistics automation across the secondary processing facility.

The project delivered exceptional demonstrative results including:

• Material return on project investment exceeded estimates;

• Labour requirements significantly decreased through elimination of second processing shift;

• Cost of goods significantly reduced;

• Throughput volume design increased output by 50%, within existing infrastructure, and

• Design capacity and capability now exceeded; with facility operating at 165% original throughput. 

The project required careful coordination of equipment and automation integration, refrigeration systems, and civil works while maintaining operational continuity. NIRAS managed permitting and authority relationships throughout the development process.

Redefining food processing efficiency standards

This project demonstrates how strategic facility optimisation can address growing food processing demands while improving operational efficiency. The project was a very compelling investment and is now delivering returns daily to Hazeldenes.

The substantial reduction in labour requirements, achieved through proven and acute automation application rather than wholesale replacement, demonstrates how processing facilities can adapt to changing workforce dynamics. NIRAS’ ability to create competitive tension in procurement and accurate performance specifications has created great benefits for Hazeldenes.

The cold chain and logistics improvements contribute to improved quality standards, intralogistics efficiency and longer effective product shelf life. Factors that are increasingly critical in global and local food supply chains. By achieving significant capacity increases within existing infrastructure footprints, the project provides a model for sustainable growth in food processing.

The rapid return on investment achieved through operational improvements rather than just capacity expansion highlights the value of comprehensive process analysis in facility upgrades. This approach enables food processors to meet market demands while maintaining competitive positioning through improved efficiency and reduced processing and operational costs.

"I worked with NIRAS on their doing the conceptual and process design for a major upgrade to Hazeldenes processing infrastructure. We are very happy with the process design and throughput balance across the whole site and on each line. We are confident that the outcome will meet the design requirements and deliver the business case’s operational and financial outcomes."

"NIRAS also assisted Hazeldenes with master planning across other infrastructure in our supply chain. This work bought a lot of clarity to our longer-term capacity, capability and capital expenditure requirements. I would recommend NIRAS to any protein processing organisation looking to improve their production capability.” 
Jonathon Hutchings - Development Director - BGH Capital

NIRAS look forward to the opportunity to continue to assist Hazeldenes in the sustaining, optimization and growth of their entire world class supply chain.