Whakatu Apple Packhouse

The Whakatu Apple Packhouse: Design and engineering the largest packhouse in the southern hemisphere.

Location

Hawke's Bay, New Zealand

Client

T&G

Project Value

$100 million

Project Status

Project completed

WSP was initially approached by T&G to design the stormwater and trade water systems for the Southern Hemisphere’s largest apple packhouse. Our engagement blossomed into a broader partnership, with WSP overseeing a range of services for T&G.

WSP VIDEO

Like WSP, T&G has a deep-rooted history in New Zealand. Starting as a modest fruit auction company in Tāmaki Makaurau Auckland 125 years ago, T&G has evolved into a global brand, known for supplying premium and fresh produce to over 60 countries.

In 2021, T&G commissioned a state-of-the-art, automated packhouse. The new space will produce more than 125 million kilograms of apples per season, doubling its current volume.

WSP were chosen for our ability to integrate with the T&G team. We formed a strong project team dealing to the challenges that were continually put in front of us.

Trent Downing Client-Side Project Manager, WSP in New Zealand

Trent Downing Client-Side Project Manager, WSP in New Zealand

T&G needed significant upgrades to their packhouse to meet increasing consumer demands, as their existing facility couldn’t handle the projected production volume.

Initially hired for preliminary design work , WSP’s role expanded to advising on resource consent renewals. As our partnership with T&G strengthened, WSP was appointed client-side project manager. Our support extended to geotechnical investigation, traffic engineering, environmental planning, master planning, business case support, procurement, and construction management.

WSP assisted with the preparation of board papers, the internal and external engagement, managed all contract procurement and project financial management.

We now have an ongoing relationship with T&G which has flourished following our delivery of the packhouse. We have an excellent relationship and one that allows T&G to tap into the diverse range of skills WSP has to offer. Ongoing work includes environmental planning, structural design, project management and surveying

Trent Downing Client-Side Project Manager, WSP in New Zealand

Trent Downing Client-Side Project Manager, WSP in New Zealand

The Whakatu Apple Packhouse was delivered nine months ahead of the original programme, on budget and can accommodate for future growth.

Despite challenges such as COVID lockdowns, labour shortages, rising material costs and international supply issues, the new packhouse was completed ahead of schedule and within budget.

WSP in collaboration with the client, contractors, and our project partners was dedicated to ensuring the facility met “world-class” standards. The project integrates the latest technologies to optimise efficiency. Working collaboratively with automation engineers, WSP assisted with the procurement of state-of-the-art robotics and machine automation to significantly reduce labour demands. This had additional benefits in terms of reliability and Health & Safety.

Since its recent upgrades, the Whakatu packhouse is the largest and most automated apple packhouse in the Southern Hemisphere. WSP worked with T&G to ensure that the building could keep up with future demand by designing it to allow for a second package line to be added within the next five years.

WSP leveraged our regional and multi-disciplinary teams to achieve these results.

We were able to leverage off the vast range of skills and disciplines to support the successful delivery of this project. Where we didn’t have the required skills locally, we used resources from across Aotearoa to support the project. Review and verification of preliminary designs were typically supported nationally to ensure we were providing T&G with the best possible outcome for the project.

T&G see our value and we are now assisting with the delivery of other projects around the country.

The project has strengthened employment in the Hawke’s Bay region.

The introduction of automation to the packhouse allowed T&G to move away from seasonal employment contracts. Instead, employees have a full-time contract which sees them working in the packhouse over the summer and working in the orchards during the winter. This solution provides better job security for the workers in the region, as well as accommodates for periods of labour shortages.

WSP provided essential survey services for the development of a new packhouse and office space. Initially, they conducted topographical surveys using UAV technology and ground methods, ensuring accurate site mapping for the design phase. During construction, WSP offered ongoing survey setout and monitoring to maintain adherence to design specifications. Additionally, they completed a cadastral survey for the property's subdivision and the creation of easements, defining property boundaries and legal access rights. WSP's comprehensive services were vital from design through to construction and legal formalities.