Opportunity
The project involved the design and construction of a 300,000 LPD milk processing unit, capable of producing a range of traditional dairy products such as pouch milk, dahi, butter, and ghee, along with various skim and whole milk powders. The unit was intended to serve both Modi Group’s own brands as well as institutional supply to major MNCs like Nestlé and Mondelez. As a greenfield project, this was Modi Group's first factory in Bikaner, Rajasthan, marking a significant milestone in their expansion into the dairy industry.
Solution
PMG was brought into the project after a significant portion of the design and execution had already been completed. Our primary role was to guide the project to ensure full compliance with food safety, hygienic engineering standards, and the rigorous Quality Assurance (QA) and Quality Control (QC) audits required by institutional buyers like Nestlé. Our scope included reviewing and improving the process design, ensuring all P&IDs were accurate, including CIP for all sections, and validating the SCADA implementation for proper operations and maintenance. We also focused on refining the plant design, which involved optimizing the master plan, building and equipment layouts, piping design, man-material movement, factory zoning, and implementing effective zoning barriers. Additionally, we consolidated and compiled all necessary QA/QC documentation, while coaching the factory team on operational standards and audit readiness. On the execution side, we supervised the completion of civil finishing works, and oversaw mechanical, electrical, and automation installation and commissioning to meet Nestlé's stringent QA/QC requirements. We also supported the factory team through the Nestlé audit process, presenting on behalf of Modi Dairy, and ensuring any issues identified by the auditors were promptly addressed.
Outcome
Our team, with extensive expertise in designing and executing projects compliant with global food safety and hygienic engineering standards, was well-equipped to deliver high-quality consultancy services for Modi Dairy. Having successfully supported other co-manufacturers for global MNCs like Nestlé and Mondelez, we were confident in executing the project right the first time, within the available budget and timeline, to meet Nestlé’s stringent QA/QC audit standards for Wet Mix Quality SMP. We faced several key challenges, including the need to quickly educate and train factory staff unfamiliar with Nestlé’s expectations and standards, convincing company management to invest in essential compliance tasks they initially deemed unnecessary, and developing and organizing critical design and quality documentation under tight deadlines. Overcoming these challenges was made possible by our result-oriented approach and unwavering commitment to our clients’ success.
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