As the logistics landscape rapidly evolves to meet consumer demand, the world’s biggest brands are building smarter. For Mondelēz International, the global company behind Cadbury, that meant reimagining distribution as a future-ready, high-tech operation. At 47,000 square metres, double the size of the MCG, the Truganina National Distribution Centre (TNDC) is more than just the largest automated Cadbury facility in the world. It’s a first-of-its-kind, sustainability-led logistics hub built by FDC to move millions of snacks with speed, precision and minimal environmental impact.

Powered by solar panels, 11 robotic cranes and 17 levels of automated storage, TNDC’s main mission is to get Australia’s favourite treats into more hands, more efficiently. That includes every Cadbury product made in Australia (including 4 million blocks of chocolate weekly) as well as locally made treats and snacks from Pascal, The Natural Confectionery Company, and Olina’s Bakehouse.

The facility consolidates the company’s national logistics into one intelligent hub, reducing truck movements while increasing speed to shelf, and cutting emissions in the process. Or, as Wayne Angus, VP of Supply Chain for Mondelēz ANZ & Japan, put it, “Our need was a technologically advanced, high-volume facility, and we required a team that could be agile, innovative, and collaborative in their delivery of this project. FDC was a trusted partner who brought creative solutions and a high level of expertise and teamwork to all aspects of this build.”

Built for the biggest brand in the business

Delivering Australia’s largest operational site for Cadbury meant pushing construction and coordination to new heights, literally. A standout feature of the facility is the 32-metre-high Automated Storage and Retrieval System (ASRS) by Swisslog, within the 11,550 square metre high bay area, requiring a level of design integration rarely seen in industrial builds.

To achieve this, FDC flipped the standard construction process. Instead of erecting steel first, the team poured the high bay slab, before structural works began. It was a calculated move, one that fast-tracked the program, improved safety and created a stable surface to support the complex install of the ASRS infrastructure.

“The usual sequencing just wouldn’t have made sense for a facility of this scale. By working closely with Mondelēz and our project partners from day one, we were able to deliver a smarter approach, one that saved time, reduced risk, and created a cleaner construction environment for this highly technical fitout,” said FDC VIC General Manager, Cameron Jackson. “This project demanded technical expertise and innovative construction techniques. From early concept design to completion, FDC ensured we met the exacting storage compliance and climate-controlled needs of a confectionery storage facility, to injecting creativity in how we manoeuvred complex, large-scale elements.”

In one of the project’s more dramatic moments, mechanical plant and rooftop equipment were airlifted into place via helicopter, a move that avoided the need for oversized cranes and allowed simultaneous progress across different construction zones. It was a high-impact example of the approach that underpinned the project.

TNDC also includes 28 vertical recessed docks, a further 12 on-grade docks, a 25-metre super canopy, 5,000 square metres of expansion-ready low bay warehousing, and capacity to manage 150 vehicle movements daily.

Green from the ground up

Since its delivery, TNDC has created more than 200 new jobs, with 90% filled by locals. Mondelēz International Japan, Australia and New Zealand CEO, Toby Smith, said the $130 million investment in the new facility was a vote of confidence in the future of Australian manufacturing and Cadbury’s long-standing presence in Melbourne. “We’re proud to make this investment in Australia, proud to create jobs in Melbourne’s west and proud that the biggest automated facility for Cadbury anywhere in the world is right here in Truganina,” he said.

TNDC may be a powerhouse facility serving up snacks-as-fuel to Australians nationwide. But the real magic lies in its future-focus, fully powered by renewable energy including a 1MW Solar Power System and a 5-Star Green Star rating by the Green Building Council of Australia for its sustainability credentials. As for construction, 30% of the build was powered by solar, 90% of construction waste was diverted from landfill, and ongoing water-saving initiatives such as rainwater harvesting and modern recycling systems have been built into operations. “We worked closely with Sustainable Development Consultants and an independent commissioning agent throughout the project, to ensure every element met or exceeded expectations,” says Jackson. The result? An impact score of 92%, and a blueprint for large-scale, sustainable construction.

From the beloved glass-and-a-half Cadbury Dairy Milk to the mighty automated crane, every part of this project came together to deliver something truly extraordinary. Proof that when smart construction meets sweet ambition, the results speak for themselves.

Celebrating 35 Years + Counting.