CASE STUDY

Inghams | Site Infrastructure Improvements

Inghams engaged Caliber Design to provide ongoing project engineering support across a series of infrastructure, safety, and layout upgrades spanning both processing and farming operations. With individual projects ranging from $20,000 to $3 million, many were at varying stages of approval and procurement. Caliber engineers were embedded within Inghams’ project delivery team to progress design, coordination, and installation activities, keeping momentum on critical works and ensuring alignment across suppliers, contractors, and internal teams. To date, Caliber has successfully delivered more than $10 million in capital projects for Inghams.

KEY TASKS

• HAZOP management and safety compliance upgrades (LN₂ systems, emergency shutoffs, O₂ sensors)

• Civil and building works (office refurbishment, façade and carpark upgrades)

• Farm infrastructure, drainage, and water reticulation improvements

• Commissioning support and handover documentation

HOW WE DELIVERED

Working closely with Inghams’ engineering and operations teams, Caliber engineers provided the technical capacity and on-site presence required to advance multiple concurrent projects. Key achievements included:

• Freezer Racking Replacement: Delivered a capital project to replace freezer racking with integrated sprinklers, pedestrian walkways, and safety systems, maintaining 246 pallet spaces while repairing structural floor damage.

• LN₂ Systems: Managed the transition from an 11,000 L to a 48,000 L LN₂ vessel and pipeline upgrade, decommissioning the CO₂ system and securing building consent for expanded capacity. Implemented HAZOP safety actions including new sensors, relief valves, and seismic supports.

• Refrigeration Upgrade: Coordinated multi-stage replacement of aging Freon equipment with a glycol/CO₂ system, improving efficiency and eliminating environmental risks.

• Automation and Facilities: Supported the installation of an automatic palletising robot and conveyor redesign, achieving reduced manual handling, minimised downtime, and projected NPV gains exceeding $670K. Managed refurbishment of the Auckland office, including roofing, fencing, and carpark works to enhance site safety and presentation.

• Farming Operations: Delivered infrastructure upgrades across multiple farms. This included new generator quick-connect kits, LED lighting, heating and ventilation systems, wastewater disposal tanks, and drainage networks. Designed and implemented reliable chlorine water reticulation and gravity-feed systems to improve animal welfare, biosecurity, and operational efficiency.

Our engineers built strong cross-department relationships and became trusted contributors within Inghams’ project delivery framework. They achieved certifications in multiple Health & Safety disciplines, including permit issuer/receiver, confined space entry, hazard and risk management, working at height, and Inghams’ Responsible Control Officer training. By stepping in to drive delivery, Caliber ensured alignment between suppliers, contractors, and internal teams, enabling critical works to progress efficiently and safely.

Throughout all projects, Caliber maintained clear communication with contractors, suppliers, and internal stakeholders. By proactively managing procurement, scheduling, and documentation, we ensured continuous progress despite long-lead equipment and live production constraints.