Opportunity
The state-of-the-art Sayona Fruits mega factory was designed to produce 9 tons per hour (TPH) of fruit pulp in 180L drum packs, 7.5 TPH of aseptic juice in 200ml and 1000ml packs, and 6 TPH of PET juice in 250ml, 500ml, and 1000ml variants. The facility's construction followed a prefabricated, box-in-box factory concept, adhering to global food safety and hygienic engineering standards. The manufacturing process is supported by a robust network of industrial services units, designed with sufficient redundancy to ensure operational reliability.
Solution
The scope of work for PMG encompassed a comprehensive range of engineering and design services, including master planning, layout engineering, and process design support. This was followed by complete MEP (Mechanical, Electrical, and Plumbing) design, detailed engineering, Bill of Quantity (BOQ) estimation, and supplier/contractor evaluation. Key industrial services equipment included a water treatment plant (60 cum/hr), air compressors (600 CFM), steam boiler (12 TPH), refrigeration plant (400 TR), cooling towers, a fuel storage tank farm, electrical substation (5 MVA), effluent treatment plant (500 KLPD), and HVAC systems (200 TR). Additionally, PMG handled industrial services distribution for air, water, steam, and chilled water, both through internal and external pipe racks. Fire protection systems were meticulously designed with fire zoning, detection, alarms, sprinklers, hydrants, and suppression systems. Electrical works included comprehensive distribution systems, lighting, grounding, backup power solutions (diesel generators and UPS), while also covering security, surveillance, and communication systems for data, telephony, and alarms.
Outcome
The remote location of the project site presented significant challenges in timely procurement, installation, and commissioning, necessitating meticulous accuracy in calculating the bill of materials for each sub-section. Another major hurdle was managing the large number and diversity of equipment suppliers and contractors, as the project aimed to reduce capital expenditure by avoiding a turnkey design-build approach. Effective coordination and information sharing were crucial to prevent rework and ensure flawless execution.
To address these challenges, our team engaged extensively with stakeholders early on to align expectations and optimize project plans, which were then signed off before proceeding. Leveraging advanced design tools such as Autodesk Revit and Autodesk MEP, we consolidated all design information in a single, easily modifiable platform. This facilitated precise BOQ estimation and prioritized procurement based on lead times. Clearly defined battery limits for suppliers ensured transparency during execution and startup. Continuous online support was provided to the Civil Construction team to accelerate civil works.
The PMG Design Team conducted monthly site reviews during the early stages, and two PMG engineers were stationed full-time on-site during execution to assist mechanical and electrical contractors. Thanks to PMG’s end-to-end expertise in food and beverage project design and execution, we successfully supported the project from concept to commissioning, and the trust built with the client allowed for dynamic scope improvements during the project's execution.
Back 
PMG stands for Projects Management Group. We provide state-of-the-art Engineering Services to build world-class food processing factories. 
Engineering is the difference between Chaos and Excellence. If you are going to do it, do it right. 
Explore the diverse range of Products in the Food Processing Industry. 
Explore the technologies at the heart of the the Food Processing Industry. 
