Greenfield flavour facility
International Flavours & Fragrances (IFF)
Glanbia is a global nutrition group with products sold in over 130 countries worldwide. In 2011, Glanbia Ingredients Ireland Ltd. (GIIL) created a state of the art dairy facility at Belview, Ireland. It was designed to produce a range of high quality dairy and nutritional powdered milk ingredient products. It was the largest single capital investment in Ireland by an indigenous Irish company. Belview is now being expanded to increase the throughput by over 50%.
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Food Sector Director
PM Group began working on this project in 2011 at feasibility and concept design stages. We progressed onto site selection and master planning, basic and detailed design, regulatory licence applications (planning, fire safety, IPPC), procurement, construction management and start up assistance. First product from the facility was delivered in December 2014.
Phase 1 consisted of a dairy intake facility, milk processing, evaporation, drying and powder handling and filling facilities. The key process elements were two GEA spray dryers with associated packaging equipment filling into 1 tonne & 25kg sacks.
Following the successful completion of Phase 1, PM Group was again retained by Glanbia (GIL) to provide EPCM services for a further expansion at the Belview site. Phase 2 will facilitate the continued growth of production by the company’s farmer-shareholders.
This is a fast track project with on-going construction work is due to finish in December 2018 and the increased capacity will be operational for peak milk production in early 2019.
On completion, the facility will consist of 3 large spray dryers running in parallel capable of producing both high quality powders and Infant Formula Ingredients. The plant will be fully automated from milk intake through to final packaging.
To reduce risk and ensure the design allowed for a fully integrated facility, we used the latest 3D modelling design tools. Through our world class BIM capability extended from the design phase through to construction, start‐up and handover. Glanbia were able to see how the extension would evolve and the high level of integration before a single stone was turned.
Minimising water use was a key goal and to achieve this, the plant treats all water evaporated from the milk using Reverse Osmosis (RO) and Ultra Violet (UV) treatment. This treated water is then reused throughout the facility minimising the use of fresh water from municipal sources.
Energy efficiency was also a critical criteria and there are many sources of heat recovery throughout the plant to achieve a significant reduction in energy required.
Glanbia's expansion construction project
Food Sector Director