How PMG Engineering is Redefining Food Factory Design with Hygienic & Cost-Efficient Solutions

Vol .05-Issue .01 | July, 2025 NEWSLETTER PMG Engineering specialises in designing and building world-class food and beverage factories. We provide a single-window solution to all engineering from concept to commissioning. info@pmg.engineering | www.pmg.engineering S S T T N N E E T T N N O O C C Common Engineering Fixes That Cut Costs and Boost Sustainability in Food and Beverage factories TECHNICAL ARTICLE From Concept to Commissioning — How to Build New Food and Beverage Factories Right from Day One TECHNICAL ARTICLE Built for Safety: Why Hygienic Engineering is the Backbone of Food Processing EXPERT INSIGHT PMG Featured in Food Marketing and Technology Magazine’s Dairy Special Edition COMPANY NEWS PMG Driving End-to-End Engineering for Farmley’s a High-Capacity, Scalable Dry Fruits & Nuts Manufacturing in Uttar Pradesh COMPANY NEWS 30 TPD Dry Fruits and Nuts Processing Factory PROJECT UPDATE 03 05 07 09 10 11 TECHNICAL ARTICLE Common Engineering Fixes That Cut Costs and Boost Sustainability in Food and Beverage factories The smallest inefficiencies can snowball into significant costs. From chilling systems running at half capacity to water and energy losses you can't even see, the hidden drains in your plant may be costing more than you think. In fact, utilities alone can account for 15–30% of total operating costs in food and beverage manufacturing. With increasing input prices and tightening sustainability regulations — like EPR guidelines, FSSAI’s water usage norms, and even EU carbon reporting standards for exporters — plants that don’t proactively optimize their utilities risk falling behind both financially and compliantly. The good news? You don’t need major equipment overhauls to make a real impact. Smart, hygiene-focused engineering can deliver leaner operations, and better resource recovery — and that’s exactly where PMG Engineering comes in. What’s Going Wrong in Most Plants? What’s Going Wrong in Most Plants? Here are recurring issues observed during audits and design reviews across dairy, beverage, and food processing plants: Oversized chilling systems: Many chilling plants operate at 1.5x to 2.0x their required tonnage, wasting energy with no load modulation or variable frequency drives (VFDs). Compressed air leaks: Air systems are often poorly maintained, with micro-leaks causing 20–30% loss of generated air. Just one 1mm leak at 6 bar can waste over ₹1.2 lakh a year. Single-use CIP systems: Many plants discard caustic after a single cycle. Reusing rinse and caustic through a three-tank system can save chemicals, water, and time. Hygiene design issues: Pipe dead legs longer than 1.5D violate EHEDG and 3-A standards. These increase cleaning times, hold-up volume, & product loss. Top-performing food and beverage facilities don’t rely on guesswork — they optimize based on engineering audits and real-world performance metrics. Here are a few proven strategies in action, many drawn from PMG’s own projects: Recovering thermal energy from pasteurized milk to preheat raw milk can reduce boiler load by 25–30%. Conducting air audits, adding VFDs, and installing inline dryers has helped large dairies save ₹3–4 lakh/month by reducing compressor run-time. Automated transitions, conductivity monitoring, and correct flow velocities (>1.5 m/s) have reduced caustic and water use by up to 35%. Switching from butterfly to mixproof valves allows simultaneous CIP and product flow, eliminating cross- contamination risks and reducing downtime. These aren’t just design ideas — they’re tangible fixes with measurable results. 03 PMG Newsletter July, 2025 TECHNICAL ARTICLE What Makes PMG Different? At PMG, we specialize in process and hygienic engineering for the food and beverage sector. Unlike generic MEP a deep understanding of actual plant realities — from utility balancing to cleaning validation. consultants, we bring Here’s how we help: Sized Utility Design from Day One production patterns — We start with a detailed process load analysis based on theoretical actual assumptions. This ensures all utility systems are neither oversized nor undersized, saving from unnecessary capex while optimizing energy efficiency. We design with only the buffer actually need considering peak hours—ensuring for uninterrupted plant operation. not In-House Designing We don’t rely on what vendors provide. Instead, we develop our own detailed P&IDs for every utility system, making sure each line, valve, and loop is placed for maximum performance, hygienic flow, and cleaning efficiency. This approach helps us eliminate dead legs, simplify layouts, and reduce product losses during cleaning or switchovers. Energy and Utility Audits with Expert Engineering For existing facilities, we conduct energy and utility audits, identifying real gaps and missed opportunities — not just on paper. Every recommendation we make is backed by engineering drawings and redesigned layouts, so you know exactly what’s possible and what’s worth investing in. Working in the interest of the client We support our client in integrating equipment like heat exchangers, VFDs, valve matrices, and flow meters and others. Since PMG doesn’t manufacture or sell equipment, our guidance is 100% unbiased and in clients best interest. Our only goal is to make sure plant runs better — not to push a product. Busting the Myths Let’s clear up some common misconceptions: Our engineering adheres to global standards like EHEDG, BIS, ASHRAE, and USFDA hygienic design norms. And we only work with food and beverage manufacturers — so we speak your language. Don’t Wait for a Compliance Notice to Act Efficiency isn’t just about saving today — it’s about building a plant ready for tomorrow’s audits, expansions, and sustainability demands. And it starts with small, smart fixes that add up. Here’s how you can get started: Conduct an review of your utilities and cleaning systems. Identify high-consumption area :- chilling, compress air, water, CIP, others. Reach out to PMG to discuss your plant challenges :- our expert team of engineers is ready to help you resolve them with practical, industry-specific solutions. Explore what’s Factory Assessment :— and uncover the savings hiding in plain sight. possible various by "If it’s running, it’s fine." "New equipment will solve it." Not true. Most inefficiencies don’t shut down your line — they silently drain lakhs each year Equipment alone isn’t the answer. True efficiency comes from engineering around your actual process and load patterns. "We’ll fix it in the next expansion." Delaying fixes today can increase your future CAPEX and operational footprint. Fix now to build leaner later. 04 PMG Newsletter July, 2025 TECHNICAL ARTICLE From Concept to Commissioning — How to Build New Food and Beverage Factories Right from Day One Planning a food or beverage factory? Discover the real engineering checklist that leading F&B companies follow. Avoid delays, ensure hygiene compliance, and build a future-ready plant with expert insights from PMG. Why Every Detail Matters in Food and Beverage Factory Planning Common Pitfalls Where Most Projects Go Wrong Setting up a food or beverage manufacturing unit goes far beyond just buying land and installing machines. It's a long-term investment—one that must meet evolving food safety regulations (like FSMS, HACCP, and ISO 22000:2018), productivity goals, and operational scalability. Here’s why it’s critical: Over 70% of new factories face rework or layout modifications in their first 3 years Downtime due to contamination or poor layout can cost companies up to $10,000/day (Source: Food Engineering Magazine, 2023). Statutory non-compliance can result in shutdowns, lawsuits, or re-approvals. When every square meter and every utility line impacts product quality and throughput, the planning phase defines your success. Despite best intentions, many projects stumble due to: Vendor-led planning: Equipment suppliers often push layouts that fit their machines, not product or process flow. Neglected hygienic zoning: Inadequate separation of clean vs. unclean areas leads to microbial risks. Missing utility planning: Improperly designed pipelines or recurring bottlenecks. low-capacity utility rooms create Lack of structured documentation: No Design Basis Report (DBR), missing scope documents, or undefined stakeholder roles, causing delay and risk of project cost increase. What Top F&B Manufacturers Do Right Industry leaders take a structured, data-backed, and process-first approach. Here's how: Conducting Feasibility Studies before any investment— financial modelling, utility needs, and production scale mapping. 05 PMG Newsletter July, 2025 TECHNICAL ARTICLE Performing Process Flow and Material Flow Analysis (MFA) to eliminate cross-contamination and Adopting to Zoning Standards as per EHEDG and 3-A SSI to design controlled zones for personnel and material movement. Implementing scalable utility design for chilled water loops, CIP/SIP loops, ETP sizing, compressed air redundancy, etc. Zoning That Works — By Design, Not by Enforcement We don’t just suggest hygiene zoning or cleanroom segregation — we design the factory layout in a way that makes procedural compliance inevitable. The layout itself ensures the right workflows, personnel movement, and material segregation — without needing additional enforcement or manpower. Good design means your process complies automatically. Using modular building blocks in layout to allow future expansion without disrupting current operations. Project milestone tracking, BOM finalization, and procurement planning. Source: EHEDG Guidelines, ISO/TS 22002-1:2009, Codex Alimentarius Why PMG Is the Right Partner for New Food Factories We understand that food factory setup is an engineering project—not just a civil construction task. Our approach combines process integrity, hygienic design, and lifecycle thinking. Whether you're a first-time founder or an experienced manufacturer, our approach remains the same: process- first, purpose-built, and precision-driven. Here’s what makes us different: We Start with What Matters Most — The Process The first step in every PMG project is defining the Process Block Diagram and the Factory Flow Sheet. This is non-negotiable, and for a good reason. Even if clients believe they’ve "seen similar factories" or have been "running plants for years," skipping this foundational step is a shortcut that leads to expensive rework and operational inefficiencies later.We ensure that every architectural and engineering decision — from the layout to the utilities — is deeply rooted in your exact process. Debunking some Myths for you! Utility Planning, From Day Zero We don’t wait for vendors to be finalized or POs to be released. Leveraging our decade-long experience across multiple factory projects, we estimate average and peak utility requirements at the conceptual stage itself. Whether it’s steam, chilled water, compressed air, or power, we identify realistic loads and plan infrastructure. Transparent Documentation & Stakeholder Alignment We document everything and share everything so there’s no ambiguity. From the start, all stakeholders are aligned. We do not fear knowledge sharing — your team is always in the loop, and our process is built on clarity, not dependency. Simulation Without Spending any amount Before a single rupee is spent on land, machinery, or civil work, we deliver, architectural Layout, Plant Elevations, and A 3D simulation of the entire facility infrastructure. This early-stage visualization gives all stakeholders a clear understanding of space utilization, process layout, infrastructure scope, and potential bottlenecks. It’s one of the most powerful tools we use to eliminate surprises during construction. Did You Know? Poorly planned F&B factories face 80% higher costs in retrofitting and 60% more downtime within the first 3 years. Plants with structured hygienic zoning reduce contamination risks by 70% (EHEDG Study, 2021). Retrofitting utility rooms can cost 2.5x more than getting it right at concept stage. “I will just replicate another factory layout that worked elsewhere.” Every process has different utility loads, hygiene zones, and product flows. Copy-paste layouts often fail. “I will handle documentation once construction starts.” Over 60% of project delays come from documentation gaps during construction. “Vendors will help me plan my layout.” “I will figure out compliance later.” Vendor-driven layouts serve their machines, not your process flow. Food safety and regulatory compliance must be built into the design from Day 1 06 PMG Newsletter July, 2025 EXPERT INSIGHT Built for Safety: Why Hygienic Engineering is the Backbone of Food Processing H ygienic engineering isn’t just about keeping things clean — it’s about building safety into every pipe, panel, and process. In this expert insight, Process Engineers from the PMG team shed light on this often-overlooked foundation of food safety. From smart equipment design to cross-functional collaboration, they reveal how thoughtful engineering choices prevent contamination, extend shelf life, and ensure regulatory compliance. Q1. Why is hygienic engineering such a critical aspect in modern food processing plants? Hygienic engineering ensures that the entire production setup—from equipment to layout—is designed to prevent microbial contamination, reduce allergen cross-contact, and ensure effective cleaning. It's not just about hygiene but about minimizing risk across every production shift. Poorly designed welds, dead legs, and uncleanable surfaces Listeria monocytogenes or Salmonella, especially in RTE (Ready- to-Eat) and dairy segments. pathogens harbor can like is much more than Food engineering today just processing and preservation. It plays a vital role in ensuring food safety, optimizing energy and water usage, food improving shelf-life, and designing smart production systems. With for sustainable and healthy food, engineers are using . increasing demand Q2. What are some key hygienic design one should ensure during equipment selection? Equipment should follow EHEDG or 3-A standards. Technically, this means: Surface roughness (Ra) < 0.8 µm for cleanability. No dead ends or crevices—all piping and product contact areas must be self-draining. Use of food-grade stainless steel (AISI 304 or 316), especially in acidic or salty product environments. Prefer welded joints over threaded connections, and equipment that allows Clean-in-Place (CIP) or Clean- out-of-Place (COP) functionality. Q3. Where do most hygienic originate, and how can they be prevented? failures Failures typically occur at interfaces—like between utility lines and product zones—or due to inconsistent cleaning protocols. A key example is improper gasket maintenance in a pasteurizer, leading to microbial ingress. Prevention lies in design reviews before installation, routine hygienic audits, and ensuring maintenance follows validated SSOPs (Sanitation Standard Operating Procedures). 07 PMG Newsletter July, 2025 EXPERT INSIGHT Q4. How can hygienic engineering improve shelf life and reduce recalls? Consistent hygiene reduces microbial load on the product from the start, which directly correlates with longer shelf life and product stability. For example, implementing air handling systems with HEPA filters in packaging areas can reduce mold spore contamination, adding 10–15 days to the shelf life of bakery items. This proactive design approach drastically reduces the chance of spoilage, customer complaints, and product recalls. Q5. How collaboration design? important in interdepartmental implementing hygienic is It’s critical. Food technologists and Process Engineers must align with engineering, QA, and maintenance teams. While engineering may focus on mechanical technologist ensures design efficiency, supports food safety goals. Clear documentation— P&IDs, cleaning validation records, drain flow diagrams food the and shared hygiene zoning protocols foster better alignment. Communicating the “why” behind design changes (e.g., segregating allergen zones) improves buy- in across departments. Q6. What’s your advice to plants trying to retrofit hygienic design in existing setups? Start with a hygienic risk assessment. Prioritize high-risk areas (e.g., open product zones, CIP systems). Focus on low-cost high-impact changes like: Re-routing drains away from process zones. Adding air curtains or pressure differentials packaging areas. in Installing easily cleanable light fittings. Training staff on hygiene zones and movement protocols. Also, create a long-term upgrade plan aligned with production shutdowns to minimize disruption. 08 PMG Newsletter July, 2025 COMPANY NEWS PMG Featured in Food Marketing and Technology Magazine’s Dairy Special Edition PMG Engineering, shares the company’s journey and approach to solving modern engineering challenges in dairy. Dr. Pandey highlights how PMG ensures precision in layout design, embeds food safety and sustainability into future-ready every project, and delivers scalable, factories. His views reflect PMG’s deep-rooted expertise in building hygienic, high-performing dairy plants aligned with Indian and global expectations. The Dairy Special Edition was curated to showcase the contributions of industry players advancing dairy manufacturing in India. PMG’s inclusion highlights its increasing leadership role in hygienic food factory design and reinforces its commitment to engineering food-safe and efficient production systems. PMG Engineering has been featured in the June 2025 edition of Food Marketing and Technology Magazine – Indian Edition, as part of the publication’s Dairy Special Segment. This edition highlights innovations and thought leadership shaping the future of India’s dairy industry — and PMG is proud to have contributed both expertise and insight. PMG’s presence in the issue includes two impactful pieces: A technical article titled “Hygienic Engineering in Dairy Processing” An in-depth leadership interview: “Engineering the Future of Dairy Processing: PMG Engineering” In Conversation with Dr. Abhinav Pandey The article emphasizes that hygienic engineering is not just a compliance exercise — it is the backbone of modern dairy factory design. With growing demands for food safety, traceability, and global compliance, the article explores what hygienic engineering entails, why it is critical in dairy, and how PMG applies these principles through zoning, personnel flow control, utility planning, and more. PMG also outlines internal design philosophy built on extensive hands-on experience and regulatory alignment. its The featured interview with Dr. Abhinav Pandey, MD of 09 PMG Newsletter July, 2025 COMPANY NEWS PMG Driving End-to-End Engineering for Farmley’s a High-Capacity, Scalable Dry Fruits & Nuts Manufacturing in Uttar Pradesh PMG is proud to be onboarded as the end-to-end engineering partner for Farmley’s new Dry Fruits and Nuts Processing Factory in Uttar Pradesh. This greenfield facility is a key part of Farmley’s expansion strategy following recent funding and growing consumer demand. As a rapidly scaling brand with existing facilities in Madhya Pradesh and Bihar, Farmley is investing in a world-class manufacturing unit designed for high throughput, automation, and food safety. The facility is being developed with a strong focus on hygienic design, operational efficiency, and scalability, aimed at supporting Farmley’s expanding product portfolio and growing demand across India and global markets. PMG will be involved from the ground up—ensuring that every aspect of the plant, from layout planning to utility integration and food safety compliance, is executed to the highest standards. PMG’s shall support with the engineering design, plant layout, process and utility systems (HVAC, electrical, integration, and project firefighting), automation management. The design prioritizes hygienic zoning, optimized material flow, and integration of reusable and automated Systems to reduce manual dependency and improve consistency.The factory is expected to deliver: 2–3X higher throughput than legacy systems 50% manpower reduction through automation Enhanced product quality and safety compliance Scalability for product diversification and market responsiveness PMG’s “first-time-right” approach ensures the facility is built for long-term efficiency, minimal downtime, and aligned with Farmley’s vision of operational excellence. in our continued This project marks another step commitment to delivering specialized engineering solutions for the food and beverage manufacturing industry. View Full Project Page 10 PMG Newsletter July, 2025 PROJECT UPDATE 30 TPD Dry Fruits and Nuts Processing Factory Client Connedit Business Solutions Private Limited Brand Name: Farmley VOLUME 01 Location Uttar Pradesh, India Sector: Dry Fruits and Nut Processing Schedule Apr 2025 – Ongoing HIGHLIGHTS Targeting 50% reduction in manpower through automation Automating key manual processes to achieve increased capacity Optimizing costs by integrating existing equipment and utilities Source: https://images.app.goo.gl/oTq2fNuCZpN4pegr8 SCOPE Feasibility check for relocate of existing factory to new location Plot selection suitable for Current expansion requirement and future expansions Upgrade the traditional process to automated and hygienic infrastructure Turnkey Design for Factory including, process, Mechanical, Electrical, and Quality. PROGRESS Space Program for deriving actual plot area requirement, important for site selection. Plot optimal utilization with necessary green area and offset requirement fulfilment. Successful completion of project basic design stage for alignment. Initiation of project management plant by deriving baseline scope, cost and timelines 11 PMG Newsletter July, 2025 KEY CLIENTS 12 PMG Newsletter July, 2025 V O L . 0 5 - I S S U E . 0 1 | J U L Y , 2 0 2 5 Build World Class Food Factories Our Services Contact us Scan Here Engineering Design 1504, Office Tower, Bhutani City Center, Sector 32, Noida Procurement and Contracting Project Management Construction Supervision Factory Assessments Technical Services Website : www.pmg.engineering Reach us: info@pmg.engineering