THE BRIEF
PMG's end-to-end engineering for Shellz's ~50 TPD confectionery & snacks hub at Sonipat - masterplan, detailed design, procurement, PM and construction
HIGHLIGHT
Consolidating scattered Delhi confectionery operations into one Sonipat hub
HIGHLIGHT
End-to-end engineering: basic + detailed design
HIGHLIGHT
PM and construction supervision
HIGHLIGHT
Reuse of existing equipment + targeted automation to control CAPEX
HIGHLIGHT
Hygienic zoning and allergen control across a wide SKU range
HIGHLIGHT
SCADA with condition monitoring and data logging
HIGHLIGHT
Future-ready layout with provision to scale
OPPORTUNITY → SOLUTION → OUTCOME
Opportunity. Shellz, a fast-growing confectionery brand, ran its manufacturing across several Delhi-area plants at limited capacity and on scattered sites, constraining its ability to meet rising demand. It acquired a facility at Sonipat to consolidate operations into a single, modern hub with room to expand, and needed an engineering partner to make that transformation work.
Solution. PMG took on the end-to-end engineering. Starting with basic engineering - master layout, hygiene zoning and segregation, utility distribution, HVAC and machine-foundation design - alongside a process and infrastructure gap analysis, PMG then delivered full detailed engineering across process, utilities, HVAC, public-health, electrical/instrumentation and SCADA, with tender-ready BOQs, and is carrying the project through procurement, equipment relocation, project management and construction supervision.
Outcome. The design brings Shellz's scattered, capacity-constrained lines under one roof at Sonipat - hygienically zoned for food safety and allergen control, combining reused equipment with targeted automation to optimise cost and throughput, and laid out to scale and diversify as demand grows - strengthening Shellz's ability to respond quickly while holding its quality standards.
KEY CHALLENGES
Capturing accurate equipment and utility data from the old facilities
Adapting the pre-built Sonipat structure to the new operational flow
Designing confectionery and biscuit lines with strict allergen control
Managing a wide SKU range
Integrating existing and new equipment with minimal disruption
WHY PMG ON THIS PROJECT
PMG is Shellz's single, end-to-end engineering partner for consolidating confectionery and snack operations that were spread across multiple Delhi-area units into one modern Sonipat hub. The design reuses sound existing equipment alongside targeted new automation to control CAPEX, is zoned for hygiene and allergen control across a wide SKU range, and is built to scale - delivered as one coordinated package from basic engineering through procurement, project management and construction supervision.
FAQ
What was the scope of this project?
PMG is the end-to-end engineering partner for Shellz's brownfield consolidation of its confectionery and snacks operations into a single ~50 TPD facility at Sonipat, Haryana - covering basic engineering, full detailed engineering (process, utilities, HVAC, building/civil, electrical and instrumentation), SCADA, procurement and contracting support, project management, existing-equipment relocation and construction supervision.
What is the capacity scope of this project?
A consolidated confectionery and snacks facility of about 50 TPD, merging previously scattered, capacity-constrained lines into one Sonipat hub with provision for future expansion.
Why did Shellz undertake this project?
Its confectionery operations were spread across multiple Delhi-area plants running at limited capacity. Shellz acquired a Sonipat facility to consolidate them into one modern, scalable hub and meet rising demand.
What did PMG's engineering scope include?
Factory masterplan and hygiene zoning, process and mechanical, utilities, HVAC, public-health engineering, electrical and instrumentation, and SCADA - each with tender-ready BOQs - plus procurement support, project management, equipment relocation and construction supervision.
How were cost and timeline optimised?
By reusing sound existing equipment alongside targeted automation rather than an all-new line, and by running the project on a 'First-Time-Right' approach with weekly progress and Gantt tracking through the build.
How are food safety and allergen control handled?
Through hygienic clean/non-clean zoning, planned man-material-waste flows and pressure-cascade ventilation, designed to manage a wide SKU range with strict allergen segregation.
