Cure.Fit – 6 KLPD Cold Pressed Juice Unit

 

Project Scope

The Cold Pressed Juice brand Rejoov, recently acquired by CureFoods, aimed at building a new Production Facility to scale up their production volumes to 21,000 bottles / day. Previously they were operating from a kitchen-scale unit producing 2,500 bottles/ day.

Additionally, they intended to extend their shelf life from presently 3 days to 3 weeks, using the High Pressure Processing Technology. Plant automation, in stages of fruit washing, cold pressing, bottling and filling, etc. is also considered.

A description of High Pressure Processing (HPP) from one of suppliers of the machine – Hiperbaric.

A description of Rotary High Speed Rinser, Filler, Capper Machine from one of the suppliers – Hilden.

The complete project design follows Lean Principles and Uniform Flow of Materials without any cross-movement of Man and Material. The factory is divided into Hygienic Zones, with suitable HVAC systems for each zone (basic, medium, and high hygiene zones). The factory is equipped with Amenities Block, Offices, Process Lab, RM-PM-FG Warehouses, etc. Hygienic Civil Construction with full underground drainage with Acid/Alkali-proof Tiling, Double-skin Doors, UPVC fixed-glass windows, etc. is considered.

The Utilities include industrial grade Water Treatment, Air Compressors, HVAC, Chiller Units, Electrical Panels and Control, Fire Protection, CCTV and Surveillance.

PMG Deliverables

  • Project Concept Design (Production Capacities, Project Phases Planning) for Project Kick-off
  • Project Management Plans – Scope, Cost, Schedule, Quality, Resource, Safety, Quality – and approval from CureFoods Management
  • Selection and Evaluation of Land Plots for setting-up the Factory
  • Factory Master Plan, with Building and Machinery Layout
  • Process Flow Sheet and P&ID
  • Equipment Layout and Elevations, with Room Sizing
  • Equipment Design, Specifications and BOQ
    • Process Equipment
    • Industrial Services Equipment (Air Compressors, Water Treatment Plant, Chilled Water Plant, Electrical Panel, HVAC and Ducting, Fire Protection System, Drainage Network, etc.)
  • Techno-commercial Evaluation of Suppliers and Contractors
  • GFC Drawings (Civil, Process, Mechanical, Electrical, etc.)
  • Supervision of Civil Works, Equipment Installation and Commissioning Works

 

Differentiated Value Creation

Cold Pressed Juices is a new Product Category in Indian Market with only Raw Pressery and two minor players in the market segment. The Process an Plant design is not mature yet, and the manufacturers have been following a traditional approach to material storage, juicing, filling and packing.

The wide exposure of PMG team to overall Beverage segment and associated engineering expertise helped create insights and actionables on designing this factory for the future years, few steps ahead of present competition. This required multiple rounds of stakeholder discussions to change the mindset, from a traditional low-capex (but high opex) strategy to future-ready low-opex facility with 100% traceability, zero rework, and following principles of Lean and Food Safety.

The lack of an experienced project team at Cure Foods with Food Industry experience was another big constraint, wherein PMG Team patiently explained all the technicalities associated with a superior design selection for the project, to several stakeholders with relatively no exposure to Food Processing Industry, towards a collaborative and learned project progress with teamwork and customer buy-in, instead of bull-dozing one’s way to decisions.

The project activities of design, procurement, installation and commissioning is anticipated to be completed in record time of 24 weeks. This has been possible due to 24×7 Live Support by PMG Team to the project concerns, ensuring no slack due to delayed decision-making.

Schreiber Dynamix – 16 TPH Juice Manufacturing

Project Scope

The project envisaged construction of a new Juice Factory with capacity of 16 TPH producing 200 mL and 1000 mL SKU’s. The project spanned 12 months end-to-end including Civil Building works, and Equipment Installation and Commissioning.

The project aimed to onboard only the top suppliers for plant and machinery. Tetrapak was given order to supply the process machinery, and PMG Team as entrusted with work of Design and Execution Supervision of Industrial Services including high capacity Water Treatment Plant, Boiler Upgradation, Steam Compressed Air, Effluent Treatment, overall Electrical Power and Lighting, and Pipe Bridge and Pipelines.

The design and installation of Industrial Services was especially challenging as the project targeted to upgrade/ increase capacity of the already available utilities e.g. bio-mass boiler, effluent treatment plant, etc. without disrupting the production/ operations of existing food park.

PMG Deliverables

Basic and Detail design of Industrial Services

  • Study existing utilities infrastructure at Fazilka Mega Food Park (Building, Boiler, Refrigeration Plant, Electrical and Power, Effluent Treatment, Cold Stores, Warehouse, etc.) and develop key engineering documents (flowsheet, p&id, equipment layout and elevations, piping and electrical distribution, etc.) to conduct condition assessment
  • Design and plan the necessary upgradation works for existing utilities
  • Design the new utility systems (Water Treatment Plant, Air Compressors, Electrical LT, Transformer, Diesel Generators, and others) and utility distribution pipe-rack & piping
  • Active deliberation and coordination with all stakeholders for first-time quality and 100% stakeholder alignment
  • Developing User Requirement Specifications (URS) for each requirement with complete BOQ and details, key expectations and performance parameters
  • Floating enquiries, soliciting offers from suppliers and contractors, techno-commercial evaluation and recommendations, and supporting Client’s purchase team towards releasing timely purchase orders and advances.
  • Review and approval of shop drawings of each supplier, and integrating all drawings into one master drawing to check for clashes and harmony in design
  • Develop and issue Good for Construction (GFC) drawings to contractors for execution
  • Factory visits to key suppliers to ensure quality and timeline of delivery is pro-actively tracked and all issues which could risk project objectives are resolved.
  • Support in Factory Acceptance Test (FAT) before dispatch from Supplier, and Site Acceptance Test (SAT) to verify performance parameters before final payments

Differentiated Value Creation

  • All utilties upto the battery limit of Tetrapak were installed and tested, ready for production, in advance of installation of Tetrapak equipment
  • Ensuring stakeholder alignment at all stages of the project among Schreiber Dynamix, Fazilka Food Park, Tetrapak, Utilties Suppliers, PMG Design Team, and other stakeholders

The intensive and timely nature of the design works, hand-holding of procurement works (led by client Purchaser), and pro-active follow-up with every major and minor supplier and contractor, enabled our design team to achieve above objectives.

Having good knowledge and experience of food safety considerations and hygienic engineering standards in factory design, we gave several in-scope and out-of-scope inputs across the project design and execution. At PMG, we believe once we are onboard a project, the overall project objectives become our responsibility, and it doesn’t matter if certain scope of project may not be under our purview or not.

Typical engineers may be good at engineering but are weak at project reporting, which includes tracking day-to-day progress, making visual reports and presentations for senior management, etc. However, across the project, our team delivered timely reports with good content – true status of site and pro-active insights on future risks, which helped senior management at Schreiber Dynamix take early decisions to continually steer the project in right direction.

Mahaan Foods – Bakery Mix Unit

 

Project Scope

The project envisaged to construct a state-of-art 6TPH Dry Mixing and Packing Facility to cater to the Food Ingredients business, especially HoReCa segment, meeting the global standards on Work Safety, Food Safety, Hygienic Engineering, GMP, and Zoning principles. Using the most advanced engineering process systems (conveying, batch preparation, mixing, packing) and production environment (HVAC, Zoning, and other controls), the factory would be unparalleled with comparison to all other competitor units.

Conceptualised as a greenfield unit, only sharing the land plot with the existing Hathras Manufacturing Unit, the unit possess independent Industrial Services, Warehouses, Control Rooms, Offices, and Amenities.

 

PMG Deliverables

As the end-to-end Engineering Design and Project Management consultant, our work scope included

  • Concept Design (Scope, Schedule, Budget, Quality Expectations) 
  • Basic Design (Key Equipment Sizing, Master Planning, Layout Engineering, Civil Architectural Design, Techno-commercial Bids for Key Scopes)
  • Detail Design (Work Breakdown Structure, Detail Specifications and Drawings, Supplier/ Contractor Identification and Procurement, GFC Drawings)
  • Project Execution (Site Supervision and Management of Civil Works, Installation and Commissioning Works – Mechanical, Electrical and Automation)

 

Differentiated Value Creation

At PMG, we possess deep understanding of the Supplier and Contractor network in Food Industry, ranging from near-acceptable to best-in-class quality, and from economical scales to premium strata. Such understanding, enables us to expend Client Capex into carefully chosen project segments which create maximum overall value.

Mahaan Foods, unlike Nestle or Mondelez (or any Global MNC), didn’t have well established product brands in this particular segment. Therefore, Capex Expenditure had to be reasonable, sufficient for short-term and suitable for long-term resilience. We ,therefore, firstly prioritized the project investment into clearly identifiable scopes, to move forward on the best-return procurement policy. Secondly, we deliberated with key Suppliers in-depth on our exact requirements, which were a mix of high productivity and flexibility, given the cost of downtimes/ changeovers in recipies, but the diversity of the Ingredient-mix portfolio we were aiming at. Finally, we ensured each individual component specifications and implementation met the industry expectations and standards, fully aware that the strength of the system is defined by the weakest element.

In nutshell, we were able to fully respect the complexity and customization required in design of the facility, due to our internal breadth of knowledge, flexibility for client inputs (which are never clear on Day 1), and robust selection of individual suppliers and systems. Striving for vertical start-up of the factory, given no precedence or template, is what PMG Team brings particularly to this project, made possible by the full scale knowledge and experience in all fields related to Food Industry – Process, Civil, Mechanical, Electrical, Automation, QA/ QC, Plant Engineering, Procurement, Construction, and others.

Pernod_Ricard_SPX_static_mixer

Pernod Ricard – Evaporation Loss Reduction

 

Project Scope

Pernod Ricard is the leading global brewery manufacturer, with several owned-factories and other co-manufacturing units. In several of their Units in INDIA, they were facing the unique issue of Product Loss across the processing chain, for which they identified PMG for root cause analysis, and recommendation to minimize the same. A prototype project at Behror, Rajasthan unit was conceived to deliberate on the problem and possible solutions.

The primary cause of product loss was identified, as the exothermic dilution of GNS and CAB, two alcoholic variants, in water which was taking place in a Blending Tank, with Air Vents and Agitation. The subsequent evaporative cooling led to ~1.0% to ~1.5% of the product leaving the tank into the atmosphere.

Subsequently, PMG Team zeroed-in on the Solutions possible, and was given Turn-key job of Design, Procurement and Installation of the system, which included High Turbulence Inline Mixing and Indirect Cooling System.

 

PMG Deliverables

  • Root Cause Analysis (RCA) of the Product Loss issue taking place across the Product Manufacturing Line.
  • Conceptualize technically-feasible and economically-viable solutions, with recommendation, for detail discussions and review with Pernod Ricard management. The solution should not alter, or affect the existing production operations.
  • Turn-key Design, Procurement and Installation of Inline Mixing and Indirect Cooling System

 

Differentiated Value Creation

Alcoholic drinks industry in INDIA operates under high surveillance by the Government Customs officials, and any change in manufacturing facility demands a major compliance rework. Therefore, one of the project objectives included a modular solution, plug-and-play design, which can bring benefit without any cost of compliance overheads and production loss. Secondly, the problem wasn’t understood in technical terms, and the loss mostly cited to Handling, Cleaning and Metering Loss – and was acceptable being present across all years. Only recently, when the Losses trend was analyzed for Summer vs Winter conditions, a variation was observed, inclining the root cause to something other than generic production losses.

PMG Team was able to identify the root cause in 1-2 weeks, wherein firstly production trials were carefully conducted and monitored at each step, to (a) Identify the Loss (b) Measure the Actual Loss. Secondly, the actual losses measured were compared with the theoretically possible values as derived from from the Chemistry laws and equations. Upon unmistakable correlation, the root cause was concluded, and in next 1-2 weeks the best-case solution with scope, time, cost, and other measurable variables was presented, which quickly got approval from Pernod Ricard management.

The complete project was delivered in 8 weeks. There was some installation issues highlighted by Factory team, which were addressed in full on priority. The system performed as per design philosophy, and is under review. Upon successful delivery for consistent period of time, the concept is expected to be replicated in other Pernod Ricard units as well.

Newly_weds_Foods

Bakery Premixes – Greenfield Project Execution

Project Scope

The customer is a recognized and premier global manufacturer of customized breaders, batters, seasonings, and functional ingredients in the food processing and food service industries. With several global manufacturing facilities across the world, the customer was setting up it’s first factory in INDIA in Vadodara, Gujarat with state-of-art machinery and plant design.

The project required high quality delivery and execution for

(a) Stainless Steel Structures (80% pre-fabricated to meet project timelines)

(b) Equipment Installation and Pipeline Fabrication

with highest standards of Construction Safety.

At PMG, we anticipated this requirement as an opportunity to couple our food industry design knowledge and experience with state-of-art pre-fabrication and site fabrication setups and resources. Not many in Indian Food Engineering domain possess the capability to prefabricate upto 80%, simply because of lack of engineering know-how and experience.

Our full time team of Safety Managers and Safety Supervisors, with experience in similar expectations at Nestle, Schreiber Foods, etc. were fully capable to understand and deliver the client expectations.

PMG Deliverables

  • ~35 Tons of Stainless Steel Structures, with 80% pre-fabrication at workshop and balance fabricated and erected at site.
  • ~90 Tons of Equipment Installation with Low Overhead Space in most locations, due to box-in-box factory concept + pre-fabricated steel structures
  • Pipeline and Pipe Rack fabrication Jobs
  • Commissioning Manpower Support

Differentiated Value Creation

Hygienic Engineering is a complex topic, which encompasses multitude of subjects – Civil, Process, Mechanical, Electrical, Cleaning, Maintenance, Quality, and many more. To deliver a work scope, in a food factory, ensuring concepts of hygienic engineering and food safety required wide engineering and food-safety know-how and experience.

PMG Team having delivered engineering projects across the food sector, from liquid dairy to infant products, and to the benchmark-setters of hygienic engineering – Nestle, Mondelez, etc. understand the severity of standards against respective food product/ factory. Our team was able to understand the expectations and produce the confidence in customer over a qualified project planning and execution. A part of this exercise included pre-order visits to PMG Head Office and Fabrication Workshop.

Given our credentials and experience, we were able to deliver the complete scope meeting project objectives of Scope, Schedule, and Quality. We were also able to identify pro-actviely and absorb certain design issues, during the course of execution, without impacting the project timelines. The site and workshop team, were provided continuous support by the Head Office team, to resolve any and all issues, on war-footing.

Nestle Lanka – 30 TPD Coconut Milk Powder Manufacturing

Project Scope

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PMG Deliverables

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Differentiated Value Creation

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vadilal-ice-creams-project

Vadilal Industries – Complete Factory Renovation

Project Scope

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PMG Deliverables

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Differentiated Value Creation

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schreiber-dynamix-project

Schreiber Dynamix – Process Study and Optimization of New Plant

Project Scope

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PMG Deliverables

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Differentiated Value Creation

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parag-milk-foods-project

Parag Milk Foods – Process Upgradation and SCADA

Project Scope

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Typi non habent claritatem insitam; est usus legentis in iis qui facit eorum claritatem. Investigationes demonstraverunt lectores legere me lius quod ii legunt saepius. Claritas est etiam processus dynamicus, qui sequitur mutationem consuetudium lectorum.

PMG Deliverables

Lorem ipsum dolor sit amet, consectetuer adipiscing elit, sed diam nonummy nibh euismod tincidunt ut laoreet dolore magna aliquam erat volutpat. Ut wisi enim ad minim veniam, quis nostrud exerci tation ullamcorper suscipit lobortis nisl ut aliquip ex ea commodo consequat. Duis autem vel eum iriure dolor in hendrerit in vulputate velit. esse molestie consequat, vel illum dolore eu feugiat nulla facilisis at vero eros et accumsan et iusto odio dignissim qui blandit praesent luptatum zzril delenit augue duis dolore te feugait nulla facilisi.

Differentiated Value Creation

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patanjali-tezpur-project

Patanjali Ayurved – Engineering Design and Construction Management

Project Scope

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Typi non habent claritatem insitam; est usus legentis in iis qui facit eorum claritatem. Investigationes demonstraverunt lectores legere me lius quod ii legunt saepius. Claritas est etiam processus dynamicus, qui sequitur mutationem consuetudium lectorum.

PMG Deliverables

Lorem ipsum dolor sit amet, consectetuer adipiscing elit, sed diam nonummy nibh euismod tincidunt ut laoreet dolore magna aliquam erat volutpat. Ut wisi enim ad minim veniam, quis nostrud exerci tation ullamcorper suscipit lobortis nisl ut aliquip ex ea commodo consequat. Duis autem vel eum iriure dolor in hendrerit in vulputate velit. esse molestie consequat, vel illum dolore eu feugiat nulla facilisis at vero eros et accumsan et iusto odio dignissim qui blandit praesent luptatum zzril delenit augue duis dolore te feugait nulla facilisi.

Differentiated Value Creation

Lorem ipsum dolor sit amet, consectetuer adipiscing elit, sed diam nonummy nibh euismod tincidunt ut laoreet dolore magna aliquam erat volutpat. Ut wisi enim ad minim veniam, quis nostrud exerci tation ullamcorper suscipit lobortis nisl ut aliquip ex ea commodo consequat.