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Project

180 TPD Chocolate and Confectionary Factory

Opportunity

Shellz, a rapidly growing confectionery brand with manufacturing operations in Delhi, has existing plants that are operating at limited capacities and spread across different locations, leading to inefficiencies and constraints in meeting rising market demand. To overcome this, Shellz acquired a facility in Sonipat and initiated the consolidation of operations into a single, modern manufacturing hub—while also building provisions for future capacity expansion. PMG was appointed as the end-to-end engineering partner for this transformation. In Phase 1, PMG delivered Basic Engineering solutions including the master layout, zoning and segregation plans, utility distribution (from generation points to consumption), HVAC systems, and machine foundation designs. As part of our strategic engagement, we also conducted a comprehensive process and infrastructure gap analysis—ensuring the new unit not only resolves current capacity constraints but also provides a scalable platform for future innovations and product diversification.

Solution

PMG is executing end-to-end engineering services for Shellz’s new brownfield facility. The project began with a comprehensive assessment of current operations and detailed consultations with key stakeholders to align with future growth needs. Our team is finalizing the plant layout with a strong focus on space utilization, hygienic zoning (FSSAI & HACCP), and efficient material flow. The design combines reusable equipment with modern automated systems, ensuring productivity while optimizing costs. We are also delivering complete designs for HVAC, electrical, and utility systems, prioritizing energy efficiency, clean air delivery, and regulatory compliance. Guided by our “First-Time-Right” approach, the project is being executed with a commitment to quality, safety, and timely delivery.

Outcome

The collaboration between PMG and Shellz is delivering a high-capacity, future-ready facility that brings all operations under one roof, eliminating the inefficiencies of scattered, low-capacity plants. The new unit is designed to achieve advanced automation and streamlined workflows that enhance overall efficiency. The layout emphasizes hygienic zoning and regulatory compliance, embedding food safety into every stage of production, while also providing the flexibility to scale and diversify product lines as market demands evolve. Once completed, the Sonipat facility will not only resolve capacity and operational challenges but will also strengthen Shellz’s market position, enabling faster responses to demand surges while upholding the premium quality standards the brand is known for.

Project Highlights

Factory moved without disrupting production and maintained business continuity

Polymer confectionery and biscuit lines merged into one future-ready facility

Existing assets and targeted automation used to reduce CAPEX and improve efficiency

Food-safe hygienic design with efficient process flows meeting global standards

Automation of key tasks increased throughput and supported market leadership

Key Challenges

Difficulty in getting accurate equipment and utility data from the old facility

Designing one site for polymer confectionery and biscuit operations with allergen safety

Adapting the prebuilt Sonipat structure to new operational flow

Managing a wide SKU range with strict allergen control

Automating complex processes and integrating equipment with minimal downtime

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Project Status

In-Progress

Services Provided