Sayona Fruits – 9 TPH Pulp and Juice Manufacturing
The mega factory of Sayona Fruits was envisaged to manufacture 9 TPH Fruit Pulp in 180L Drum Pack, 7.5 TPH Asceptic Juice in 200ml and 1000ml Pack, and 6 TPH PET Juice in 250ml, 500ml and 1000ml variants.
The complete construction was planned in pre-fabricated structure with box-in-box factory concept, meeting global food safety and hygienic engineering standards. The process scope was duly supported by robust Industrial Services units, networked with sufficient redundancy.
Video Presentation of the Sayona Manufacturing Facility.
The work scope of PMG included:
- Master Planning, Layout Engineering and Process Design Support
- Complete MEP Basic Design and Detail Engineering, with Bill of Quantity (BOQ) Estimation and Supplier/ Contractor Evaluation
- Industrial Services Equipment
- Water Treatment / Storage Plant (60 cum/hr)
- Air Compressors (600 CFM)
- Steam Boiler (12 TPH)
- Refrigeration Plant (400 TR)
- Cooling Towers
- Tank Farm for Fuel Storage
- Electrical Substation (5 MVA)
- Effluent Treatment Plant (500 KLPD)
- HVAC Systems for Air Conditioning (Process, Ventilation, Cold Rooms – 200 TR)
- Storm/ Rain Water Harvesting
- Weigh Bridges
- Industrial Services Distribution (Air, Water, Steam, Chilled Water, others, electrical, etc.)
- External Pipe racks for process and utilities
- Internal Pipe racks for process and utilities
- Fire Protection Systems
- Fire Zoning and Escape Routes
- Fire Detection and Alarm System
- Fire Fighting System including Sprinklers, Fire Hydrants, Foam or Gas Fire Suppression Systems
- Fire Water Reservoir tanks and pumps
- Electrical and Power Works
- Electrical Distribution System including HT and LT Panels, Power Control Center (PCC), Motor Control Center’s (MCC), APFC Panel
- External and Internal Lighting and Electrification
- Grounding and Lightening Protection
- Backup Power including Diesel Generators and UPS
- Security and Surveillance Systems
- Communication Systems – Data, Telephone, Alarms
Differentiated Value Creation
The remote geographical location of the project site posed one of the major challenges, among others, towards a timely project procurement, installation and commissioning – which demanded that the project bill of material, for each sub-section, be calculate with utmost accuracy.
Another key challenge was the high number of and diversity among the equipment suppliers and contractors, more so as the project desired to minimize the Project Capex by avoiding a turn-key design-build execution. The timely coordination and information sharing was essential to avoid reworks and deliver first time right project execution.
To cater to the unique constraints, our team collaborated extensively in the initial stage and gathered all the stakeholder expectations, and subsequently refined them to optimal, which were again signed-off before moving forward.
Subsequently, using advanced design software like Autodesk Revit and Autodesk MEP, our team was able to consolidate all project design information in one place, which was easy to interpret and modify, incrementally with new information. The bill of material (BOQ) was accurately estimated and procurement of items was prioritised basis respective lead times. The battery limits among several suppliers were properly defined, and were 100% measurable, to ensure clarity during execution and startup. Continuous online support was provided to Civil Construction team, to ensure fast civil works.
PMG Design Team visited site and took review of site progress every month initially, wherein during Project Execution stage, 2 No. PMG Engineers were mobilized full time to site, to support and guide the mechanical and electrical contractors on daily basis.
Due to the end-to-end knowledge and capabilities of PMG Team in Food and Beverage project design and execution, we were able to support the project across it’s timeline (concept design to commissioning). Further, the confidence built in the client team therein, allowed acceptance of certain dynamic improvements/ positive changes in scope, along the execution of the project.