600 KLPD Dairy Factory-Layout Engineering for Restructuring of Existing Factory

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.

BRAC's Gazipur plant had grown organically over ~25 years into a congested, inefficient site. PMG produced a clean-sheet concept masterplan for the ~60-acre factory - reorganising production, CIP, QC, storage, utilities and amenities, separating man and material flows, and planning a modern effluent-treatment plant and renewable-energy-led utilities. The redesign demolishes and restructures the messy older blocks while keeping the few newer structures in production, and uses maximum vertical expansion to preserve land for future growth.