Food Processing

Project Details

Waikato Valley Chocolates had outgrown their original factory on Hamilton’s Borman Road when they engaged Apollo Projects to design and construct a new food processing facility.

The new 2,000m² production area is divided into distinct zones for ingredients melting and standardisation, product forming and cooling, packing, and panning (the process of coating various ingredients with chocolate). These zones require careful thermal management due to significant temperature differentials, which are addressed through the extensive use of internal Kingspan insulated panels. These panels offer excellent insulation properties and meet stringent food-grade hygiene standards across all surfaces.

Product storage was a key factor, as production centres around traditional chocolate periods of Christmas and Easter. Apollo developed several scenarios for the client to consider in terms of optimal warehouse size, configuration and expandability. The resulting 1,200m² finished goods warehouse utilises post-tensioned concrete slabs for increased durability and insulated panel cladding to provide maximum thermal insulation.

Site planning was equally strategic. The building orientation and external yard layout ensure consistent shading throughout the day, essential for staging products during loading. The facility also includes a public factory outlet and modern open-plan office spaces. Staff amenities have been thoughtfully designed to support the needs of the 60 employees working across various shifts, providing a secure and comfortable environment.