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Project

Brownfield Chocolate and Noodle Manufacturing Facility

Opportunity

The Nestle India identified a significant growth opportunity by expanding production capacity to meet increasing market demand—particularly in the northern region at Sanad, Gujarat, India. The existing plot housed an operational noodle factory, but to scale up, two new process buildings are being constructed within the same site. One building is dedicated to an additional noodle production line, while the other is designed for a new chocolate processing line. This expansion not only complements the existing manufacturing setup but also allows for optimized use of the shared infrastructure and utilities. By leveraging the same location, the client aims to streamline logistics, reduce overhead costs, and accelerate time-to-market—while addressing the operational complexity of executing utility and facility upgrades adjacent to a running plant.

Solution

To support the execution of this capacity expansion within a live production environment, PMG Engineering deployed a dedicated site-based mechanical engineer and a draftsman to ensure seamless on-ground execution and technical coordination. The mechanical engineer led the daily supervision of utility-related works, coordinating with multiple contractors to maintain progress and adherence to safety protocols. Simultaneously, the draftsman managed real-time drawing control and ensured interdisciplinary alignment across civil, mechanical, and electrical teams—crucial for maintaining design integrity and avoiding rework in a fast-paced, multi-scope project. This hands-on involvement by PMG enabled efficient decision-making, reduced execution delays, and ensured that both new process buildings were integrated smoothly with the existing facility infrastructure.

Outcome

Despite the challenges of executing utility upgrades within an operational facility, PMG Engineering successfully ensured uninterrupted plant operations throughout the expansion. Our continuous on-site presence enabled proactive decision-making, seamless coordination among all stakeholders, and timely resolution of execution bottlenecks. As a result, the new noodle and chocolate production buildings progressed as planned, with utilities integrated efficiently—without compromising on safety, quality, or existing production performance. This outcome reinforced the value of close technical oversight in complex brownfield expansion projects.

Project Highlights

Utility upgrades near live plant without production disruption

Coordinating multiple contractors across diverse engineering disciplines

Meeting aggressive timelines for new facility construction

Integrating new utilities with existing infrastructure seamlessly

Ensuring safety in an active and mixed-use site.

Key Challenges

Deployed site-based engineer and draftsman for execution support

Maintained uninterrupted operations during utility upgrades

Enabled real-time drawing updates and scope alignment

Ensured quick on-site decisions and issue resolution

Achieved seamless integration of new and existing facilities.

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Location

Sanad, Gujarat, India

Client

Nestlé

Project Value SUPERVISED

$9195402.00

FOOD PRODUCTION

50 Ton / Day

Project Status

In-Progress

Services Provided