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50 KLPD Aseptic Fruit Juice Factory - Construction Supervision
Schreiber Dynamix Dairies Ltd | Oct, 2015 to May, 2017
Opportunity
The project involved the expansion of an existing 16 TPH juice factory by adding a new UHT line for 200 mL SKU and introducing new packaging variants. The entire project, including civil building expansion, equipment installation, and commissioning, was completed within a 9-month timeline. In alignment with Schreiber Foods' global safety commitment and policy, the project set a strict target of zero accidents and zero lost time during execution. To ensure this goal was achieved, the PMG Team was brought on board to oversee and manage the project's safe and timely delivery.
Solution
The supervision and management were critical in achieving the project's objectives. Achieving zero accidents and zero lost time entailed implementing a work permit system for all site works, ensuring safety and legal compliance for all contractual teams, and enforcing the use of PPE and safe work practices. PMG Engineers provided safety trainings to contractors and site engineers, conducted daily contractor field audits, and held daily toolbox talks. A safety committee was formed to oversee safety protocols, with regular meetings, emergency evacuation drills, and other safety exercises. Additionally, the project promoted safety awareness through Safety Week celebrations and other engaging activities to reinforce a strong safety culture on-site.
Outcome
The project achieved zero-accident and zero-lost time execution, accumulating over 200,000 safe man-hours while successfully fostering a safety-conscious culture across the site. Given that much of the contractual manpower, particularly for civil works, was sourced from diverse regions and often inexperienced or illiterate, the challenge of instilling safe work practices was immense. This transformation, from enforcing basic PPE use to encouraging active participation in Contractor Field Audits (CFA), was made possible by the expertise and dedication of the PMG Team. PMG's relentless commitment to their "Safe-by-Choice" principle overcame any project schedule pressures, using a balanced approach of hands-on training, strategic interventions, critical escalations, and a strong sense of ownership. This outstanding safety performance set a new benchmark within the Schreiber group, leading to PMG being entrusted with responsibility for the next expansion projects, including Line 4.
Project Highlights
Greenfield project for UHT Line
New packaging and variant of 200 mL
Zero-Accident and Zero-Lost Time Hours
Start-to-Finish in less than 9 months
Vertical Startup and Commissioning
Key Challenges
Inculcating Safety Behavioral across the Project Site
Large number of Contractors
Extreme Summer
Rainy and Winter Climates
Simultaneous Construction and Installation Works
Geographically Remote Location
Construction Supervision
₹75 Cr
Services Provided
Site Supervision & Execution Oversight
Workforce Training & Skill Development
Real-Time Progress Reporting
End-to-End Construction Management
Independent Construction Quality Audits
Quantification & Billing Certification
As-Built Records & Site Documentation