Lakeland Dairies Milk Intake & Extension Project

Tusker Construction Group is proud to be shortlisted for the ICE Awards 2026 in the category Specialist or Specialist Services Contract €1m to €10m for the Lakeland Dairies Milk Intake & Extension project in Bailieborough, Co. Cavan.

The Irish Construction Excellence Awards recognise outstanding achievement across Ireland’s construction sector, celebrating excellence in quality, innovation, collaboration and safety. Being named a finalist reflects the strength of our team, our integrated delivery model, and our commitment to delivering complex projects to the highest standards.

Project Overview

Appointed as main contractor, Tusker delivered a major upgrade to Lakeland Dairies’ milk intake facility. The scope included:

• Partial demolition and extension of the existing intake canopy
• Construction of a new entrance road and expanded yard area
• New staff and trailer parking facilities
• Two new silo plinths
• A new CIP bunded area
• Expanded surface water and effluent drainage networks
• Intake pipe bridge
• Electrical switch room and administrator room

Delivered under a fixed-price lump sum contract, the project took place during the winter months within a fully live operational environment. Maintaining uninterrupted milk intake was critical, requiring daily coordination with Lakeland staff and tanker drivers.

The completed facility now features:

• 14 raw milk intake pumps
• 8 whole milk storage silos
• 17 pasteurised storage silos
• Capacity to pump 450,000 litres per hour
• Storage for 2.5 million litres of raw milk
• 3.3 million litres of pasteurised milk
• 750 metric tonnes of cream

The result is a future-ready, high-capacity intake facility that fully meets Lakeland’s operational and safety objectives.

Delivery, Collaboration & Innovation

Delivering this project within a live processing plant demanded meticulous planning and phased sequencing. Daily whiteboard meetings ensured real-time coordination, while weekly workshops and multi-stakeholder meetings maintained transparency across the client, design team and supply chain.

Tusker’s integrated in-house capabilities — Crane Hire, Haulage, Fabrication and Design — enabled full control across all workstreams, reducing reliance on subcontractors and ensuring quality consistency.

Innovation played a key role in delivery:

• Offsite fabrication of steelwork, pipe spools and support frames
• Temporary structural works integrated into the permanent build
• Installation of a structural pipe bridge with pedestrian access
• Night-shift works to minimise disruption
• Digital site management systems and QR-controlled access
• On-site apprentice engineer implementing emerging technologies

Phased handovers allowed Lakeland to benefit from increased capacity as each section was commissioned.

Overcoming Challenges

Operating within a live facility presented significant challenges, including:

• Constrained work areas
• Strict hygiene requirements
• Complex utility interfaces
• Over 200 truck movements daily

Traffic management and pedestrian safety were critical. Tusker implemented robust traffic plans and introduced a new one-way system to improve site flow and safety.

A particularly complex element involved coordinating with ESB to bury existing 3-phase overhead power lines without interrupting supply. Through detailed planning and strong collaboration between civil and electrical teams, this was successfully completed without incident.

Importantly, the project was delivered with zero health and safety incidents, reflecting Tusker’s safety-first culture.

Quality & Excellence

The Lakeland Dairies Milk Intake & Extension stands as a benchmark project within the food processing sector. Delivered on time and within budget, the project combined disciplined execution, collaborative engagement and innovative construction methods.

The phased approach ensured operational continuity, while digital tools enhanced safety, transparency and efficiency. Feedback from the client and design team was overwhelmingly positive, praising both workmanship and seamless integration into ongoing operations.

As Paraic Maher of Malone O’Regan Consulting Engineers noted:

"Tusker delivered a modern, efficient, and future-proof milk intake facility that increases intake capacity, on time and within budget. Strong collaboration and communication across the full project lifecycle ensured a robust outcome that reflects Tusker’s commitment to meeting client needs and project objectives."

Lakeland Dairies also commended Tusker’s professionalism, proactive approach and ability to maintain uninterrupted operations throughout construction.

A Project That Demonstrates Excellence

This project exemplifies Tusker Construction Group’s commitment to excellence through:

• Doubling site capacity
• Enhancing safety through improved traffic systems
• Delivering an integrated, end-to-end solution
• Embedding innovation through offsite fabrication and digital systems
• Achieving zero safety incidents

We are extremely proud of our team and grateful to Lakeland Dairies and Malone O’Regan Consulting Engineers for their collaboration and trust.

We look forward to representing this project at the ICE Awards 2026 and celebrating alongside the very best in Ireland’s construction industry.