THE BRIEF
PMG concept masterplan to restructure BRAC Dairy's congested ~600 KLPD factory at Gazipur, Bangladesh - 2D layout of the 60-acre site, equipment loads and
HIGHLIGHT
Design for a phase wise expansion and upgradation
HIGHLIGHT
Optimize the storage space for raw and finished materials
HIGHLIGHT
Safety and efficiency risks- addressed with separate paths of personnel and materials
HIGHLIGHT
Resolving adjustments made in operations due to spatial limitations
HIGHLIGHT
Optimize the improper distribution of the utilities
OPPORTUNITY → SOLUTION → OUTCOME
Opportunity. BRAC Dairy & Food Project recognized the need to enhance production efficiency and address layout constraints within its Gazipur facility, which was build ~25 years ago. The goal was to streamline operations and accommodate projected growth through a strategic upgrade and expansion. By restructuring the factory, the client aimed to eliminate process bottlenecks, separate personnel and material movement, and optimize storage and utility zones and also address the long phaseout practice which were hard to employee due to old layout. This initiative also supported the company’s broader objectives of future readiness, safety compliance, and improved space utilization, making the factory more agile and scalable for upcoming production demands.
Solution. PMG Engineering deployed a specialized team to assess the facility’s existing layout and workflows. Using spatial analysis and operational data, a revised masterplan was created to separate man-material movements and reconfigure critical process zones. Our engineers worked closely with civil and utility teams to align on future installations within the space constraints. The upgraded design incorporated expansion provisions and improved maintenance access. Design was carefully phased to minimize disruptions to live operations. Real-time adjustments and collaborative planning ensured that restructuring aligned with safety, efficiency, and client objectives at every stage.
Outcome. The project concluded successfully, ready to transform the Gazipur facility into a more streamlined and scalable plant, when eit shall be executed. The new layout is to improve operational flow, reduced material handling times, and clearly separated personnel and material movement paths. Increase storage efficiency, and utility zones making them accessible for maintenance. Most importantly, these upgrades are planned to achieve with minimal disruption to ongoing operations. BRAC Dairy & Food Project shall now benefit from enhanced productivity, better workflow management, and a facility equipped for future growth—all delivered within a challenging active production environment.
KEY CHALLENGES
Understanding the existing facility layout & operational inefficiencies
Navigating limited space for construction and installation within an active facility
Coordinating between interdisciplinary stream in a congested environment
Managing stakeholder expectations and maintaining alignment on timelines and deliverables
Ensuring safety compliance amidst constant on-site movement and modifications.
FAQ
What was the scope of this project?
PMG prepared the concept layout engineering to restructure BRAC Dairy's existing ~600 KLPD factory at Gazipur, Bangladesh - a 2D masterplan of the ~60-acre site, equipment load details, and 3D exterior views and a walkthrough video. The brief was to turn an organically-built, congested plant into a coherent, scalable factory.
What is the capacity scope of this project?
A ~600 KLPD dairy and foods factory producing milk, UHT and flavoured milk, ghee, butter, cheese, yoghurt and lassi alongside a range of beverages, sweets and condiments - to be restructured from its congested existing layout into a streamlined, future-ready plant.
Why did the factory need restructuring?
The Gazipur plant was built about 25 years ago and expanded incrementally, leaving congested flows, mixed man-material movement, poor storage and uneven utility distribution. PMG's masterplan reorganises it into clean zones with room to scale.
What did PMG's scope include?
Concept-stage engineering design - a 2D masterplan layout of the ~60-acre factory, equipment load details, and 3D exterior views plus a video, based on a site visit. Detailed engineering and execution were outside this scope.
How does the design improve sustainability?
By planning utilities for maximum use of renewable energy, a modern effluent-treatment plant, and maximum vertical expansion to preserve land for future growth.
How is production continuity handled?
The masterplan demolishes and rebuilds the messy older structures while retaining the few comparatively new blocks, so production can continue during execution, with phasing to minimise disruption.
