22TPD Edible and Pharma Lactose Factory - Basic Design

Opportunity. The project involved the design of a 22 TPD Edible and Pharma Lactose Factory aimed at producing high-quality lactose for both edible and pharmaceutical applications. The plant was designed to meet the specific conditions of Russia, particularly the challenging low ambient temperatures. The challenge was to add a lactose powder manufacturing section to an existing facility, with limited space availability. The high production demand and the need to maintain superior product quality in food and pharma-grade lactose added further complexity to the project. The design had to be integrated into the existing infrastructure, ensuring efficient space utilization and meeting the stringent quality requirements for both industries.

Solution. PMG’s engineering design addressed both space limitations and technical requirements. The process design started with a mass balance to optimize resource use and define key process steps. A detailed Process Flow Diagram (PFD) was created, illustrating the process from raw material handling to final product packaging. To ensure control and consistency, a comprehensive P&ID was developed, covering pumps, valves, tanks, and pipelines, with clear flow paths, control loops, and safety measures. A detailed instrument list was prepared, specifying each instrument’s role, including pressure, temperature, and flow monitoring, ensuring consistent product quality and compliance with food and pharma-grade standards. The CIP (Cleaning-in-Place) system was designed to ensure hygiene, with a schedule that aligned with production cycles, detailing wash steps and fluid flow paths. The plant layout was engineered to fit within the existing facility, optimizing space while integrating new equipment such as pumps, piping, and storage. Utility design also ensured that temperature control for edible and pharma-grade lactose production was maintained.

Outcome. Despite the challenges of remote collaboration and the extreme climate, the project was completed within a short timeframe. The project presented significant technical challenges due to the brownfield nature of the facility and space constraints. However, PMG's approach ensured the lactose section was successfully integrated, optimizing the available space while meeting production demands. The detailed process design, including the P&ID and instrument list, ensured smooth operations, with precise control over process parameters and consistent product quality. The CIP system design provided a robust cleaning protocol, ensuring hygiene standards were met without interrupting production. Despite the challenges of working within an existing infrastructure, the project was completed on schedule, providing the client with a fully functional lactose section capable of meeting both food and pharma-grade quality standards.