Opportunity
The ITC Ranjangaon plant, which manufactures biscuits, finger snacks, noodles, and chips, was initially set up by modifying a non-food manufacturing facility The plant is 25+ years old and had its own challenges. As a result, PMG’s supported to assess the existing infrastructure and ensure compliance with food safety standards. The goal was to upgrade the factory in line with food safety and hygienic engineering standards, particularly focusing on infrastructure, process, mechanical, electrical, and design aspects.
PMG was engaged to provide engineering services for a comprehensive factory audit and identify subsequent upgrades, ensuring alignment with global food safety standards while maintaining operational efficiency.
Solution
PMG’s role was to deliver engineering services aimed at upgrading the plant’s infrastructure to comply with stringent food safety and hygienic engineering standards. The solution involved:
• Conducting a detailed audit of the existing facility across various domains (infrastructure, process,
mechanical, electrical, design).
• Conceptualizing an upgradation plan to address identified gaps in compliance.
• Developing a high-level cost estimate for the proposed upgrades.
• Prioritizing improvement projects based on necessity:
o Fundamentals (necessary for immediate compliance),
o Basics (strongly recommended for optimal operations),
o Good to Have (optional but beneficial for long-term improvements).
• Providing a clear roadmap for management to prioritize and execute the upgrade in phases.
The scope also included identifying design solutions that could overcome the limitations of the factory’s existing infrastructure, while minimizing costs and maintaining operational continuity.
Outcome
By the end of the engagement, a well-defined list of improvement projects was finalized, categorized according to their urgency and importance. The comprehensively identified list of works for upgradation of a 25-year-old manufacturing plant, ensuring that it met global food safety and hygienic engineering standards. By prioritizing over 50 individual improvement projects, PMG provided a clear framework for ITC to execute the upgradation in phases, aligning resources effectively and addressing compliance needs systematically. The team was able to find design solutions that fit within the plant’s operational constraints and budget, providing a high-impact strategy for the plant’s future.
In an ongoing 24x7 operations, the audit and planning phase was completed within two weeks, a significant achievement considering the plant’s multi-product manufacturing setup. The project successfully aligned all key stakeholders. This allowed the management team to take informed decisions on which upgrades to prioritize, marking the project a success in ensuring the factory's infrastructure is aligned with food safety and hygiene requirements. These prioritized upgrades are now being actively implemented, ensuring long-term sustainability and compliance for the plant.
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