Overview
When Orora Group needed to modernise its thermal system at one of its key New South Wales manufacturing facilities, they turned to O’Brien. With sustainability targets on the horizon and production demands continuing to rise, the team was looking for a smarter, more efficient hot water solution that could integrate seamlessly into daily operations.
Orora Group is a leading manufacturer of sustainable packaging solutions, supplying customers across food, beverage, and industrial sectors. With a strong focus on environmental responsibility, their operations demand high-efficiency systems that can support production without compromising sustainability goals. At their New South Wales facility, consistent thermal performance and energy optimisation are critical to maintaining output while reducing environmental impact.
O’Brien delivered a 1000kW OBYFLAME water heating system designed to reduce energy use, support unattended operation, and keep heat delivery consistent across long pipe runs. Every part of the install — from compliance to commissioning — was designed to reduce complexity and support long-term performance.
About the Site
Orora’s NSW site plays a key role in producing sustainable packaging for customers across Australia and beyond. The facility is part of a national supply chain and operates with tight timelines and exacting standards. Thermal performance isn’t a nice-to-have — it’s core to keeping output high and systems running smoothly.
The Brief
Orora needed to improve the efficiency and reliability of its water heating setup while meeting the latest safety and compliance standards for unattended operation. System compatibility, commissioning readiness, and site constraints were also critical considerations.
This wasn’t a simple equipment swap. It needed to be a fully thought-through solution, with smart engineering at every stage.
What We Delivered
- High-Efficiency Heating
We installed a 1000kW OBYFLAME hot water boiler delivering over 95% thermal efficiency — reducing fuel use, improving control, and bringing down long-term costs. - Reliable Heat for End-Use
With 40 metres between the boiler and the washer bays, we supplied a duty/standby pump arrangement to ensure stable flow, no matter the conditions. - Smarter Energy Control
Modulating burner controls provide real-time response to usage, regulating temperature precisely and avoiding unnecessary energy waste. - Ready for Unattended Operation
The system was designed and delivered to meet AS2593-2021 standards, with automated safety systems and built-in training support to ensure compliance. - Full System Integration
All work was scoped with clear P&IDs and project ownership from the start. We managed everything from design and fabrication to on-site delivery and handover.
The Result
- Thermal efficiency over 95%
- Stable performance across long pipe runs
- Reduced unplanned maintenance
- Compliant with AS2593-2021
- Lower operating costs and greater system visibility
These aren’t abstract wins. The outcome is a system that the Orora team can count on — clean, reliable heat that supports production without pulling attention away from the work that matters.
Navigating On-Site Challenges
Like many active manufacturing sites, Orora’s facility came with real-world limitations.
- Welding was restricted during install, requiring prefabrication and multiple deliveries.
- Pump control panel needs were identified late by site techs, prompting fast adaptation.
- Frequent labour changes caused by external service breakdowns added complexity.
We managed these challenges by investing time in early scoping and detailed site assessments. Our team worked closely with Orora to lock in expectations, identify constraints, and deliver an outcome that worked.
Looking Ahead
This project reflects the kind of smart, reliable engineering that defines O’Brien’s approach. This project delivered a system Orora’s team can rely on. It does the job every day, with less effort, more certainty, and fewer surprises.
Need support upgrading your thermal infrastructure? Talk to O’Brien. We design systems that hold up under pressure.
