CASE STUDY

Lion Breweries | Beverage Manufacturing Facility Upgrades

Caliber provided project engineering support across multiple workstreams at Lion’s beverage manufacturing facility. From structural refurbishments and fire safety system upgrades to automation improvements and international equipment installs, our engineer scoped, planned, and delivered projects in coordination with ongoing production. The role included stakeholder engagement, contractor management, and preparation of Capex documentation to enable confident investment decisions.

KEY TASKS

Capex proposal development and budget preparation
Coordination of international equipment procurement and installation
Cross-functional stakeholder engagement and scope definition
Design, fabrication, and commissioning of sensor and automation systems
Development of structural remediation and repair plans

Fire protection system concept design and compliance coordination
On-site contractor coordination and phased installation management
Pressure vessel refurbishment in confined spaces with safety controls
Structural assessments and corrosion mitigation planning
Walkway, stair, and platform design, fabrication, and installation

HOW WE DELIVERED

Caliber provided embedded project engineering support at Lion Breweries’ beverage manufacturing site, working across a diverse portfolio of capital works—all while maintaining alignment with ongoing production.

Our scope included managing the refurbishment of corroded wine tanks, which required confined space entry. We led scaffolding installation inside the tanks, coordinated sandblasting and epoxy recoating, and arranged pressure vessel inspections and reports—all under robust safety plans with confined space risk controls and rescue procedures.

In the ethanol brewing area, Caliber oversaw a fire system upgrade, managing the concept design and Capex proposal for new sprinkler foam technology. Working alongside fire engineers, we identified the correct foam type and determined which system components needed to be replaced to maintain compliance and performance.

For one of the site’s structural challenges, we led the remediation planning for a mezzanine floor degraded by conveyor lubricant corrosion. We engaged structural consultants, worked through repair methodologies with contractors, and developed an installation plan with full cost breakdowns to support Capex approval.

Automation upgrades included the delivery of missing bottle detection sensors on three packaging lines—covering glass, crate, and can formats. Caliber managed the entire process from mechanical design and fabrication to wiring, automation, and commissioning.

We also scoped and delivered new access infrastructure, including platforms, ladders, and stairs. Our engineer worked closely with Lion’s internal stakeholders to define requirements, develop concept designs, coordinate fabrication, and manage installation in a live production environment.

Finally, Caliber coordinated the international procurement and installation of mill roller blocks, bringing in a technician from Germany to ensure the equipment was installed and commissioned to spec.

Each project required precise planning and sequencing to avoid production disruption. Through close engagement with internal teams and external contractors, we delivered safe, efficient outcomes that aligned with Lion’s operational and budgetary goals.

Jack makes a great Project Engineer. He follows tasks through and doesn’t ask for much assistance and finds ways to get an answer. One doesn’t have to remind him of ‘general work’ that needs to be done and internal stakeholders enjoy working with him.

Hayley-Ann Adamson

Capital Programme Manager NZ, Lion