Level Electrical Geraldine and Temuka delivered a switchboard upgrade at a McCain food processing facility in Timaru, replacing ageing infrastructure and maintaining power continuity during a critical shutdown window.
At McCain Foods’ potato processing plant in Timaru, maintaining continuous operations is critical. With production running year-round, any planned shutdown presents a narrow window to complete essential infrastructure upgrades.
The team was engaged to deliver a full upgrade of the site’s main electrical infrastructure, including replacement of ageing switchboards and mains cabling to support ongoing production and site reliability. Delivered within a fixed shutdown window, the project required precise planning, coordination and execution to ensure the facility returned to full operation on schedule.
Switchboard Upgrade During Shutdown
The project centred on replacing the facility’s main switchboards, which had been in operation for more than 40 years. Careful planning ensured all works were completed within the scheduled shutdown period, with no impact to production restart timelines.
Given the complexity of the site, the team also addressed legacy issues across sub-boards connected to the new system, ensuring the upgraded infrastructure would perform reliably across the entire facility.
Scope of Work
The project included:
- Replacement of the main switchboards and mains cabling
- Installation of 2 x 2000A Bremca switchboards
- Installation of 4 x 400mm copper parallel conductors per phase
- Disassembly and removal of the existing switchboard (40+ years old)
- Temporary power setup using 3 x 80kVA generators
- Continuous monitoring and management of generator fuel and performance over a two-week period
Temporary Power and Continuity During Works
To enable other contractors to complete maintenance across the site during the shutdown, the team established a temporary power solution using three 80kVA generators.
This required 24/7 monitoring and management to ensure uninterrupted supply to lighting and essential services, supporting safe and efficient progress across multiple workstreams.
Coordinating Delivery Under Fixed Timeframes
With production scheduled to resume immediately following the shutdown, the project required strict adherence to programme timelines. The team worked efficiently to complete the upgrade while resolving unforeseen issues within the existing electrical infrastructure.
Works were completed within a two-week shutdown window, with power disconnected on 29 December and successfully restored on 12 January, ensuring the site returned to full operation as planned.
Outcome
The upgrade delivered a modern, reliable power distribution system, replacing ageing infrastructure and improving overall site performance ahead of production restart.
With obsolete components removed, the upgraded system ensures faster access to replacement parts, reducing operational risk and improving long-term reliability.
Measurable Results
By consolidating two smaller distribution boards into the new main switchboard, the team freed up space within the switchboard room, creating capacity for future control cabinets and infrastructure without requiring additional building works.
A Coordinated Team Effort
The project brought together a large team across multiple roles, working in a tightly coordinated environment to deliver a technically demanding upgrade within a fixed shutdown window.
The result reflects the planning, communication and coordination required to deliver critical infrastructure upgrades in high-pressure industrial environments.
“Mike Wethey and his team from Level Electrical did an outstanding job installing our new main incomer board at McCain Foods during the Christmas and New Year shutdown period.
They were professional, punctual and completed the entire installation on time as promised. The workmanship was meticulous, and the team maintained strong communication throughout the project, resolving issues quickly within a very short shutdown window.
I highly recommend Level Electrical for critical electrical infrastructure work.”
Craig Burnett
Electrical Supervisor, McCain Foods NZ
Project Details
- Client: McCain Foods
- Location: Timaru, New Zealand
- Address: 62 Meadows Road, Washdyke, Timaru
- Timeline: 29 December 2025 – 12 January 2026
- Services: Electrical switchboard and infrastructure upgrade
Level Project Team
Mike Wethey, Brent Christie, George Gallichan, John Pain, Olly Beirne, Craig Hydes, Simeon Reardon, Kori Patrick, Flynn McKenzie, RJ Passion, Caleb Carter, Michael Dewe, Arno Van Wyk
Planning a complex electrical upgrade or shutdown project?
Get in touch with Level Electrical Geraldine and Temuka to discuss your requirements.
