glanbia dairy nutritionals facility Ireland
Key Statistics
Client
Glanbia Ingredients Ireland Ltd
PM Group Office
Ireland
Cost
€180m (Phase 1); €120m (Phase 2)
Size
23,500 sqm (Phase 1); 11,000 sqm (Phase 2)

Glanbia is a global nutrition group with products sold in over 130 countries worldwide. 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. The facility has now been expanded to increase the throughput by over 50%.

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Tom Waters
Tom Waters

Food Sector Director

State-of-the-art facility

PM Group began working on Glanbia's Belview development in 2011 at the 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.

The Phase 1 development 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 and 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 has facilitated the continued growth of production by the company’s farmer-shareholders. This development involved a new milk intake facility, a reverse osmosis concentration plant, evaporator, dryer, powder handling and storage with additional bagging / packing lines.

 

 

Reducing risk

The facility now incorporates 3 large spray dryers running in parallel and capable of producing both high quality powders and infant formula Ingredients. The plant is 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. BIM was central to the design, construction, start‐up and handover phases. Its use enabled Glanbia to see how the extension would evolve and the high level of integration before a single stone was turned.

The dryer was constructed on site in a temporary building and fabricated in two main sections, the dryer body and the cone.  The cone was constructed upside down and inverted as it was lifted into the building. The main body of the dryer was then lifted and installed in the building.

 

Innovating water and energy usage

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 component and there are many sources of heat recovery throughout the plant to achieve a significant reduction in energy required.

Glanbia's expansion construction project

Tom Waters

Food Sector Director