Creamy Foods (under the brand name Madhusudan) is one of the fastest growing dairy companies in North India. Having setup a new Dairy Processing Unit in their existing premises at Khurja U.P., they targeted a complete re-design of their old unit, particularly the Milk Pre-Processing Section along with addition of a high capacity 50 Ton/ Day Milk Powder Reconstitution setup and 2 No. new Continuous Butter Making (CBMM) Lines.
Further the most advanced technologies were chosen for the upgradation and capacity expansion, e.g. Scanima Mixer for Reconstitution from Tetrapak, CBMM lines from , etc. All integration was to be done by Factory and PMG team, i.e. scope of suppliers was limited to equipment supply.
The complete project design follows Lean Principles and Uniform Flow of Materials without any cross-movement of Man and Material. The section is divided into Hygienic Zones, with suitable HVAC systems for each zone (basic, medium, and high hygiene zones). Most Civil work was redone following principles of Hygienic Engineering and Food Safety, e.g. new underground drainage in SS316, Polyurethane Flooring, Double-skin Doors, UPVC fixed-glass windows, etc. A new Utilities Piperack was also laid to provide Steam, Water, Compressed Air, Chilled Water, along with Fire Protection, CCTV and Surveillance.
- Master Plan, with Building and Machinery Layout, Man Material Layout, and other details
- Integrated Process Flow Sheet and P&ID
- Equipment Layout and Elevations, with Room Sizing
- Equipment Design, Specifications and BOQ
- Process Equipment
- Industrial Services
- Techno-commercial Evaluation of Suppliers and Contractors
- GFC Drawings (Civil, Process, Mechanical, Electrical, etc.)
Differentiated Value Creation
The wide exposure of PMG team to overall Dairy segment and extensive experience on upgrading old factory setups into modern world-class integrated units with System-dependent Operations, and compliant to global standards of Food Safety and Hygienic Engineering helped in quickly identifying the needs and constraints of the brownfield project, and chalking out an optimal project execution plan.
The design of the upgraded facility was completed before the dismantling of the first to-be-replaced equipment, which led to optimal planning of new supplies and single-time continuous contractor works. Support was provided across all activities – Civil, Process, Mechanical, Electrical, Automation, Quality and others wherein available good assets were fully utilized in tandem with new equipment.