Project Bluebird, Ballarat, VIC

Project Bluebird is a cutting-edge flour manufacturing facility for Mauri, featuring a 7-storey mill, a 3-storey grain intake building and accompanying warehouse and office space. The project plays a key role in achieving Mauri’s vision for a modern production site in Ballarat, focusing on safety, quality and sustainability to support the growing demand for their products.

From the schematic design phase, the project team focused on detailed coordination within the 3D model to resolve potential conflicts before any construction work began. This model integrated all services, ensuring that every component would fit within the facility’s layout. Using detailed design modelling, system interactions were mapped out including precise penetrations with the architectural design. This early coordination provided clear guidance to contractors and allowed Mauri to visualise their workflows, providing confidence and helping to keep the project aligned with the construction program.

In flour mills, it’s vital to maintain strict moisture control. To achieve this, the water and sanitary waste pipework was relocated outside the building’s process areas and thermally insulated to maintain ambient water temperature.

In addition, we incorporated a rainwater storage system and recycled water distribution, promoting sustainability. Roof drainage is managed by eaves gutters, avoiding the use of internal downpipes and preventing rainwater from entering the process areas. We also implemented independent, precise water pressure control for sensitive items to keep equipment running smoothly during mill operation, ensuring continuous production without interruptions.

Our acoustics design focused on creating a controlled sound environment that aligns with both operational needs and regulatory standards. Through detailed assessments of noise emissions and identification of noise sensitive receivers, we incorporated acoustic treatment into the design to align with regulations and best practice. This process included analysing noise from mechanical equipment and its impact on various areas within and neighbouring the facility.

A compressed air system, designed to drive machinery throughout the mill, delivers both high performance and energy-efficiency. This system powers various equipment throughout the facility and features multiple variable speed machines to ensure smooth operation and extend the lifespan of the equipment.

The vertical transportation design includes a goods lift that moves both people and equipment across the 7-level mill. The lift is sized to accommodate the largest mill rollers and their specialised moving cradle. With hygiene as a priority, the lift meets the strict cleanliness standards required in food manufacturing, supporting smooth and sanitary operations across the facility.

Project Bluebird will deliver long-term value for Mauri and the Ballarat community. Beyond supporting Mauri’s production goals, it creates local jobs and encourages sustainable practices, positioning the facility as a leader in responsible food manufacturing.