Project Overview
Location
Dunsandel, Canterbury
Date Completed
2011
Services
Cut. Form. Build.
Installation
Engineering Support
When Tetra Pak needed to deliver some serious cyclones for dairy processing for their customer Synlait, they partnered with Longveld. Together, we engineered, fabricated, and delivered stainless-steel cyclones built to perform at scale — designed for demanding dairy environments and manufactured with precision from start to finish.
Synlait: Cyclones for 30-Tonne Spray Dryer Operations
Destined for Synlait Milk’s Dunsandel powder plant, Longveld fabricated two cyclones purpose-designed for 30-tonne spray dryers. Each unit measured 4.2 metres at the scroll and stretched 17 metres in length, making them among the largest components ever produced in our workshop.
Both cyclones were fabricated in parallel. This required detailed engineering design, careful material sequencing, and a tightly coordinated fabrication schedule to maintain accuracy across every stage of the build. Managing scale without compromising quality was central to the approach.
Engineering Design That Solves Real-World Challenges
Fabricating cyclones of this size introduces unique structural and manufacturing challenges. To reduce weld concentration and maintain strength across the conical sections, the team applied staggered seam layouts. This approach optimised material use while maintaining structural integrity and flow performance.
Each rolled panel was formed and aligned with precision. The result was consistent geometry across the full length of the cyclone — critical for reliable separation performance in dairy spray drying applications.
Fabricated in Hamilton, Delivered to Canterbury
Once fabrication was complete, the cyclones were wrapped, protected, and transported from Longveld’s Hamilton facility to Synlait’s Dunsandel site. Moving components of this scale required careful planning, specialist handling, and coordination across teams to ensure each unit arrived ready for installation.
Tetra Pak: Cyclone Fabrication Across Multiple Dairy Sites
Following the Synlait Dunsandel project, Longveld went on to fabricate 6 more cyclones for Tetra Pak. These units were delivered to multiple locations, including:
- Synlait Pōkeno
- Waikato Innovation Park
- Westland Dairy – Hokitika
These cyclones rank among the largest and most complex stainless-steel units Longveld produced during that period, reflecting our capability in large-scale fabrication for dairy processing plants.
A Long-Standing Engineering Partnership
Longveld’s work with Tetra Pak began in 2011, with continuous collaboration ever since. Across multiple dairy facilities, we have supported Tetra Pak with precision-engineered process equipment designed to meet strict performance and food-grade requirements.
This long-term relationship reflects consistent delivery — engineering design that works, fabrication that holds up, and equipment that performs in critical dairy production environments.
Fabrication Expertise at Scale
Delivering cyclones of this size and complexity requires:
- Detailed engineering design for large-scale dairy equipment
- Careful material planning for oversized stainless-steel sections
- Precise rolling, forming, and seam staggering
- Specialist welding to food-grade standards
- Coordinated logistics for transporting oversized fabricated components
Every stage is handled with focus and discipline, from initial design through to final delivery.
The Role of Cyclones in Dairy Powder Production
In dairy spray drying, cyclones act as primary separators, removing powder from the airstream exiting the dryer. Their performance directly affects product quality, recovery rates, and plant throughput. Reliable cyclone design and fabrication are essential to maintaining efficient, consistent dairy processing.
Through these projects with with Tetra Pak, Longveld delivered cyclone systems engineered to perform under pressure — built to last, and built for the realities of large-scale dairy manufacturing.
