Opportunity
Aiming to reuse bottles as part of a sustainable production strategy, Pernod Ricard India Pvt. Ltd. envisaged to setup a bottle washing facility operating at 400 bottles per minute (BPM). The project demanded innovative solutions to accommodate evolving requirements while maintaining stringent timelines and quality standards. Situated beside an existing plant, the project required efficient space utilization and integration of advanced systems to ensure seamless operations, innovative engineering to integrate advanced systems into an existing plant while adhering to Pernod Ricard's sustainability vision. PMG partnered as the Engineering, Procurement, and Construction Management (EPCM) partner by Pernod Ricard and this project positioned them among the pioneers of bottle reuse in India.
Solution
PMG’s scope included detailed engineering, procurement, and construction supervision, tailored to address the challenges of high-speed operations and evolving project requirements. A detailed process design was developed, prioritizing bottle cleaning efficiency and hygiene standards. The process design focused on optimizing flow paths and equipment layout to ensure precision and efficiency in bottle washing. A comprehensive P&ID was developed, detailing critical process parameters and instrumentation for flow, pressure, and temperature monitoring. Automation and control systems were integrated to ensure consistent performance and quality.
Industrial services, including steam, water, and air utilities, were meticulously designed to meet operational demands. The facility's utility design emphasized water conservation and caustic recovery through advanced filtration and recirculation systems, ensuring optimal use of resources. Detailed designs for instrumentation, electrical systems, and power distribution supported the high-speed facility, while civil and building engineering ensured optimal space utilization within the existing infrastructure. Vendor assessments and procurement strategies ensured the use of cutting-edge equipment that supported the reuse of bottles and minimized the environmental footprint.
Outcome
This facility stands as a testament to PMG’s engineering excellence and commitment to sustainability, establishing a benchmark for environmentally conscious production in India. By enabling bottle reuse, the project significantly reduced waste, water usage, and energy consumption, directly contributing to Sustainable Development Goal (SDG) targets. PMG’s expertise in engineering and project management ensured the facility met all performance and sustainability goals while maintaining high-speed production capabilities. The facility now delivers precision and reliability, meeting Pernod Ricard’s operational demands while setting a benchmark for high-speed beverage production facilities. Through close collaboration with stakeholders, rigorous scope management, and multiple design iterations, the project was delivered on time and to the client’s exacting standards, paving the way for more sustainable production practices in the industry.
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