200 BPM Carbonated Flavored Drink Factory

Opportunity. Sepoy Beverages LLP, a brand specializing in tonic water, initially relied on third-party manufacturing but sought to establish its own production facility to meet rising market demands and streamline operations. In 2019, PMG assisted in designing a state-of-the-art factory that would ensure high-quality standards while increasing production capacity. PMG’s role involved comprehensive planning, including the creation of a Masterplan, technology selection, evaluation, and project cost estimation. Based on market analysis and projected demand, PMG recommended a production line capacity of 200 bottles per minute (BPM). After initial cost assessments and project alignment, Sepoy engaged PMG in 2022 for detailed engineering and project execution.

Solution. PMG’s involvement spanned every phase of the project—from concept design to final implementation of commissioning of factory. The scope included detailed site planning, technology roadmaps, and capacity assessments to guide land acquisition and budgeting decisions. The design phase included Basic and Detailed Engineering, where PMG developed layouts for civil works, process flow, mechanical setups, and electrical systems, ensuring the seamless integration of production processes. PMG played a key role in procurement, collaborating closely with vendors to source high-quality equipment suitable for tonic water production by meeting the specific product requirement for small and uniformed sized bubbles for the fizz. The design prioritized automation, incorporating advanced control systems into the production line to maintain consistent quality and efficiency. During the site execution, PMG provided on-site supervision for civil, mechanical, and electrical works, ensuring quality standards were met and progress was timely. Rigorous testing and commissioning were conducted to ensure the factory was production-ready upon completion.

Outcome. The establishment of their own manufacturing facility provided Sepoy Beverages with greater control over product quality, supply chain management, and production schedules. The facility, designed to produce 200 BPM, not only met current market demands but also allowed for future scalability. PMG’s comprehensive approach—from initial design to detailed engineering and full project execution—enabled Sepoy to transition smoothly from third-party manufacturing to a fully self-sustained production facility. The project’s successful completion empowered Sepoy Beverages to efficiently meet market demand, maintain high-quality standards, and solidify their position in the competitive tonic water industry.