54 | Curle Electrical Services Challenging Fonterra project wins recognition The project aimed to modernise the cheese plant’s chilling systems. T T Bernadette Cooney CONTRACTING Hamilton-based Curle Electrical Services (CES) has once again demonstrated its exceptional capability in the industrial electrical sector by becoming a finalist in the prestigious Master Electricians Awards of Excellence 2025. The company was recognised in the $1 million to $5 million project category for its outstanding work on the Hautapu Western Refrigeration Plant project – a state-of-theart upgrade for Fonterra in the heart of the Waikato. “Being a finalist in this category is a testament to the hard work and expertise of our team,” says Duane Woods, general manager and electrical project manager at CES. “We’re proud of what we accomplished, especially with a project as challenging and transformative as this one.” The project aimed to modernise the cheese plant’s chilling systems by transitioning it from environmentally harmful R22 refrigerant to an ammonia-based system – all a part of Fonterra’s national effort to phase out R22 and reduce its environmental footprint. “This was more than just a system swap; it was about future-proofing operations,” says Duane. “Fonterra now has a more sustainable, reliable system with increased capacity, all while aligning with modern environmental standards.” The greenfield project to build a replacement facility began in 2023. The scope of works included the installation of three GEA chiller skids, two cooling towers, cooling water and chilled-water-supply pumps and two 80-cubic-metre silos. This required the construction of a new Master Control Centre (MCC building) undertaken by First Principle Construction, plus the integration of new power-supply transformers to meet increased power demand. Curle Electrical Services was engaged by Excel Engineering to undertake the design and build of the low systems and control system, collaborating with Nemesys Automation, who completed the PLC and HMI Control system set-up and programming. The project also featured equipment from industry leaders like Schneider Electric. “We did all the low-voltage design, including a new switchboard, the VSD installation, motor cabling and the PLC control system design,” says Duane. The aim was to design a control system that ensures continuous operation – 24/7, 365 days in some cases. Another challenge was designing efficient cabling routes and supports for outdoor compressors, a first for the team. “We had to rethink how we handled cable sizing and routing,” says Duane. “This was an opportunity for us to push boundaries and innovate.” The benefit for Fonterra includes enhanced reliability and greater operational efficiencies, better environmental outcomes by eliminating the ozone-depleting refrigerant and transitioning to an ammonia-based one. With modern, efficient systems in place, Fonterra’s Hautapu site is better equipped to handle future technological and regulatory changes. Curles Electrical Services has a portfolio of successful projects completed for Fonterra. This includes their involvement with Windsor Energy during the installation of a 30MW (45t/h) steam boiler, fired by wood biomass at Fonterra’s Waitoa site. This enabled the retirement of one of the existing coal boilers on site, replacing it with state-of-the-art bubbling fluidised bed (BFB) combustion. A cool store compressor upgrade at Fonterra Lichfield and a wastewater treatment plant upgrade at Tirau are other projects CES has recently completed. Founded over 20 years ago by Brett Curle, CES has grown into a leader in industrial electrical design-and-build projects across the Waikato. From its base in Te Rapa, the family-owned business employs a mix of seven skilled electricians and five electrical engineers. Along with its network of contractors, Curle Electrical Services continues to provide quality services, including electrical engineering, machine safety systems, electrical equipment in hazardous areas, control panel design-and-build to automation and system maintenance. “Our team takes pride in delivering high-quality solutions, which is not about the cheapest options, but the best options,” says Duane. 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