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.

parag-milk-foods-project

Parag Milk Foods – Process Upgradation and SCADA

Project Scope

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PMG Deliverables

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Differentiated Value Creation

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Ovobel Foods – Complete Factory Upgradation

Project Scope

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. Nam liber tempor cum soluta nobis eleifend option congue nihil imperdiet doming id quod mazim placerat facer possim assum.

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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Pernod Ricard – Clean-in-Place System

Project Scope

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. Nam liber tempor cum soluta nobis eleifend option congue nihil imperdiet doming id quod mazim placerat facer possim assum.

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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Elven Agri – HVAC Systems for Processing and Filling

Project Scope

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. Nam liber tempor cum soluta nobis eleifend option congue nihil imperdiet doming id quod mazim placerat facer possim assum.

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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skm-eggs-factory-production-floor

SKM Eggs – CIP Upgradation

Project Scope

SKM Eggs Limited, the largest egg processor in India, intended to bring online their critical systems like storage tanks, pasteurizers, etc. for continuous process monitoring, data logging, and historical trending to facilitate process and operational improvements. This required procurement and installation of instruments which could measure and transmit flow, temperature, conductivity, pressure, and other data. This was another step of many to move towards a more system dependent and less people dependent operation.

PMG Deliverables

To study existing operations and identify needs and requirements, especially where the value-add by capital spend on new instruments would be most beneficial.

Subsequently, PMG was assigned the responsibility to supply, install and commission the instruments on the existing SCADA System. Further we provided support on training the operations team on the usage and maintenance of the new instruments.

Differentiated Value Creation

Our team understands the standards and good practices at most of the global MNC’s like Mondelez, Nestle, Abbott, etc. Therefore, in addition to possessing the technical expertise, we deeply understand the value creation of certain technology or design in a particular context e.g. open feedback plant components (valves, etc.) may seem to deliver the same accuracy and information at lesser cost, but we understand the significant necessity and benefits of closed loop components. We believe in investing money is the right thing, not in partially-right things. As engineers, we want to be fool-proof, and not fool-oneself. We always educate our clients that money spent in partially-right things is money wasted. And therefore our study came out with recommendations on new instruments which where technologically advanced (to comply standards for next 10-15 years) and really useful (creating sufficiently value to the operations).

Sub-optimal communication and information exchange is the crux of most project failures, i.e. money spent but objectives missed. Our integrated design, procurement and execution team ensured that no detail (or communication) was missed across the spectrum. Our policy to procure from the best suppliers, install through the best contractors, and supervising everything by in-house engineering and quality assurance team culminated into meeting project objectives with first time quality and 100% stakeholder alignment.

raj-raisins-product

Raj Raisins – HVAC Systems for Processing and Filling

Project Scope

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. Nam liber tempor cum soluta nobis eleifend option congue nihil imperdiet doming id quod mazim placerat facer possim assum.

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.

Mahaan Foods – Hathras Factory Upgradation

Project Scope

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. Nam liber tempor cum soluta nobis eleifend option congue nihil imperdiet doming id quod mazim placerat facer possim assum.

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.

skm-eggs-director-products

SKM Eggs – Pasteurizer Upgradation

 

Project Scope

SKM Eggs Limited, the largest egg processor in India, required to upgrade their existing manually operated Egg Pasteurizer to meet the new global compliance of Mondelez, which necessitates a fool-proof production operation wherein an operator/ supervisor cannot bypass production CCPs and protocols. This required, among several other things, a SCADA-based operation, continuous monitoring of process parameters (temperature, flow, pressure, conductivity, FDV status, etc.) at 0.5 sec interval, installation of requisite instruments, new electrical panels and wiring, and eventual redesign of  the complete Pasteurizer into a skid-based unit. Both production, and Clean-in-Place operations were to be done via SCADA, with minor protocols like Cut-in Cut-out, product-utility pressure monitoring, etc. as part of every batch.

The project was to be delivered in a short time with minimal of production downtime and vertical start-up. Further since stakeholders involved not only SKM Eggs and Mondelez, but other local and foreign buyers of SKM Eggs, the final design should encompass and deliver the expectations of all stakeholders.

 

PMG Deliverables

The key objectives included

  • Supply and Installation of all necessary components (valves, instruments, pumps, electrical panel and electricals, automation, piping, structure, etc.) to upgrade the existing Pasteurizer
  • Commissioning of the upgraded Pasteurizer on all of the production recipes and generating all requisite production reports
  • Training of operations and maintenance staff on the new system

The other objectives included

  • supporting SKM Eggs team to develop, compile and provide to Mondelez Quality Assurance team the engineering, production, and quality documentation
  • Developing standard CIP recipes and CIP Validation for each of the recipes and mixes
  • Developing concept and provision to extended SCADA control and operation to Raw Egg and Pasteurized Egg storage, and other sections in future

Differentiated Value Creation

Unlike a traditional milk or cream pasteurizer, the operation of an Egg Pasteurizer is much critical as

  • a minor variation in pasteurization temperature can severely impact product properties (viscosity, flavor, etc.)
  • over the period of production, the holding tubes and other equipment start to clog, wherein the system needs to self-improvise to control heating to keep up to the pasteurization temperature yet, not leading to burning or coagulation of product
  • CIP cleaning must involve caustic and acid in each CIP, and validation of cleaning time, temperature, flow, chemical concentration is vital

With our experience in diverse food industries and end-to-end in-house capabilities we were open to new learnings and quick to improvise on standard SCADA control logic and design to suit to Egg Pasteurizers.

Sub-optimal communication and information exchange is the crux of most project failures, i.e. money spent but objectives missed. Our integrated design, procurement and execution team ensured that no detail (or communication) was missed across the spectrum. Our policy to procure from the best suppliers, install through the best contractors, and supervising everything by in-house engineering and quality assurance team culminated into meeting project objectives with first time quality and 100% stakeholder alignment.