The Client
Our client for this project is a major multinational business in the food and beverage sector, with expansive operations across Australia and New Zealand. They are a globally recognised leader known for producing a wide portfolio of popular consumer brands. This company operates several large-scale manufacturing facilities, reflecting their significant market presence and production capability within the Oceania region. Their operations are complex, highly automated, and subject to rigorous safety and compliance standards, making risk management an integral part of their business continuity and employee wellbeing strategies.
The Goal
The client was undertaking a significant greenfield development project, investing over $400 million in the construction of a new state-of-the-art manufacturing facility. As part of this ambitious build, new equipment was being supplied and installed, which needed to meet stringent Australian standards for safety and compliance.
The primary objective was to engage an independent expert to conduct a comprehensive risk assessment of the new machinery. The aim was to identify any gaps in compliance with Australian standards, particularly the AS 4024 series, and to present a clear, actionable roadmap for addressing any issues. By doing so, the client sought to:
- Gain a clear understanding of any compliance risks associated with the newly installed equipment.
- Receive a prioritised punch list of remedial actions, enabling effective engagement with the equipment supplier.
- Ensure that all machinery met the highest standards of safety before full commissioning, thereby protecting operators and optimising long-term operational safety.
- Have up to date and comprehensive machine risk assessment from day one as a reference and avoid the need to Suntory to prepare these themselves.
Why TEG Risk?
TEG Risk was a natural choice for this engagement, thanks to our longstanding relationship with the client. Over the years, we have delivered numerous hazard identification and risk assessments, and machine safety consulting assignments across their New Zealand facilities, establishing a trusted partnership built on proven results.
The client’s decision to continue working with TEG Risk was driven by our deep understanding of the food and beverage industry, our reputation for delivering high-quality, value-for-money services, and our commitment to safety. Importantly, our team’s certification through TÜV (Technischer Überwachungsverein) reassures clients of our technical competence and alignment with global best practices.
While cost is often a critical factor in this industry, this client prioritises quality and value, recognising the long-term benefits of thorough, expert risk management. Our track record, combined with our ability to translate complex technical findings into practical, operational solutions, positioned us as the preferred partner for this high-stakes project.
The Solution
TEG Risk’s solution involved conducting detailed Machine Safety Risk Assessments aligned to the AS 4024 standards for machine safety compliance, using our advanced MinRisk software to ensure clarity and consistency in reporting. This process was carefully structured and implemented over several months, coinciding with the progressive installation of equipment as the plant build advanced.
Our approach included:
- Progressive Inspections: Conducting on-site inspections in stages, in tandem with the commissioning schedule, allowed us to provide timely feedback and facilitated early resolution of potential issues.
- Standards Review: During the machine risk assessments, we benchmarked all equipment against the AS 4024 series, the cornerstone of machinery safety standards in Australia. Some of the equipment, initially designed to European standards, required additional scrutiny. In these cases, we prepared detailed reports outlining the residual risk differences between European and Australian standards, enabling the client to make informed, risk-based decisions about acceptability.
- Custom Reporting: Each assessment was tailored to machine safety standards to deliver clear, actionable insights. We provided a prioritised punch list of corrective actions, offering technical explanations and practical solutions to address each compliance gap identified.
This methodical, transparent approach ensured that the client could engage confidently with their supplier to address any shortcomings and move swiftly toward full compliance.
Challenges
The primary challenge was the dynamic nature of the project. As a greenfield build, machinery installation and line commissioning were occurring in a phased manner. This required our team to be highly adaptable, conducting inspections while equipment was still in the commissioning phase.
Timing was critical. By performing assessments during commissioning rather than waiting for full operational readiness, we enabled early detection of issues. This proactive approach minimised delays and allowed the client to implement corrective measures rapidly, ensuring the project remained on track.
Results
The outcomes of the project delivered significant value and peace of mind for the client. Our work resulted in:
- A Prioritised Action Plan: A clear, prioritised list of required actions was delivered, allowing the client to effectively engage with their supplier and drive timely rectification of all identified issues.
- Informed Decision-Making: By providing detailed insights into risks and the relevant standards, we empowered the client’s team to make well-informed decisions about the level of residual risk they were prepared to accept.
- Operational Readiness (including lock out tag out procedures): Beyond compliance, we delivered risk assessments in a user-friendly format, complete with Lock Out Tag Out (LOTO) cards and hazard overview materials. This eliminated a significant administrative burden for the client’s Health & Safety (H&S) team, who had anticipated needing to translate technical project data into operational resources themselves.
Ongoing Risk Management: The client now has access to the MinRisk platform, giving them the capability to maintain and update risk assessments as corrective actions are completed. They are also exploring the integration of this information into their maintenance management system, further embedding safety into their operational processes.