5 TPD Plant-based Meat Factory

Opportunity. PCK Agri, one of India’s leading spice brands headquartered in Indore, identified a strategic opportunity to diversify into the growing plant-based food segment by launching a range of soy-based vegan products. To capitalize on this market shift and meet rising consumer demand, the company planned a greenfield manufacturing facility with an initial capacity of 250–300 kg/hr, scalable up to 750 kg/hr in future phases. Recognizing the critical need for precise planning and execution for this new venture, the client engaged PMG to provide end-to-end engineering services. Our scope includes factory layout design, industrial utilities, HVAC, firefighting systems, electrical engineering, and comprehensive project management. PMG’s role also involves reviewing all prior work, conducting a gap analysis, and developing optimized layouts and engineering strategies that will guide the detailed design and ensure successful project execution.

Solution. To address the opportunity and ensure a smooth transition from concept to execution, PMG approached the project by first identifying gaps in the pilot plant and reviewing the preliminary designs and client-executed work. We developed a comprehensive master plan and process building layout—ensuring that the highly sensitive batch process remained unaffected. Leveraging extensive experience in designing world-class food factories, PMG incorporated best practices in food safety, hygiene, and contamination control. Our layout ensured seamless movement of personnel and materials, effective zoning to prevent cross-contamination, and integration of cost-efficient design solutions. PMG worked in close collaboration with the client to deliver a layout that not only meets current production targets but is also adaptable for future expansion. Throughout the process, our focus remained on ensuring all designs followed a “first-time-right” approach, minimizing rework and enabling smooth project execution.

Outcome. As the project progresses, PMG’s integrated engineering solutions are enabling the client to move toward a first-time-right, mass-production facility tailored to meet today’s growing demand for diverse soy-based vegan products. The factory is being developed to uphold the highest standards of food safety and hygiene while ensuring energy-efficient operations across process, mechanical, and electrical systems. PMG is also establishing a clear roadmap for future scalability and expansion, with a strong focus on seamless man and material movement and long-term operational efficiency.

PCK Agri - one of India's leading spice brands - moved into plant-based foods with a range of soy-based vegan products, and PMG is the single end-to-end engineering partner taking it from a sensitive pilot batch process to a full greenfield factory. PMG reviewed all prior work and ran a gap analysis, then delivered detail engineering across process and automation, building and civil, utilities, electrical, and HACCP-driven hygiene zoning - plus procurement, project management and construction supervision. The design is sized for an initial 250-300 kg/hr and engineered to scale to 750 kg/hr without re-layout.