Wafer Line Expansion Project: Construction Supervision

Opportunity. Britannia Industries initiated a brownfield expansion at their third-party facility, JB Mangharam, in Gwalior, Madhya Pradesh, to install a new wafer-based chocolate production line. This expansion demanded significant electrical upgrades—including a new transformer installation, replacement of old panels, integration of new panels with existing infrastructure, and ensuring proper interlocking and load sharing—all executed alongside ongoing plant operations. The project’s complexity lay in upgrading and integrating the electrical systems without disrupting current production, maintaining operational safety, and meeting the tight commissioning timeline for the new production line.

Solution. PMG Engineering deployed a dedicated site-based electrical supervision and commissioning engineer to lead the execution and integration of the electrical works. The engineer supervised daily activities, ensuring adherence to design specifications, safety standards, and schedule commitments. Responsibilities included overseeing installation of the new transformer and panels, managing replacement of outdated panels, ensuring proper interlocking and load-sharing with the running plant, and coordinating with contractors and client teams to resolve on-site challenges swiftly. Through real-time supervision, technical oversight, and proactive decision-making, PMG ensured all electrical systems were seamlessly integrated, fully tested, and ready for the commissioning of the new wafer line.

Outcome. With PMG’s on-site engineering support, the electrical upgrades were completed successfully without interrupting plant operations. The new transformer and panels were installed and commissioned in accordance with design and operational requirements, achieving reliable load sharing and interlocking with the existing systems. This ensured that the new production line was commissioned on time, with improved electrical system reliability, safety, and efficiency—delivering significant value to the client in a challenging brownfield setting.