THE BRIEF
PMG engineered Nutriti's brownfield HVP plant upgrade in Gujarat - factory assessment, a new 16 KL glass-lined reactor line, procurement and project
HIGHLIGHT
Brownfield debottlenecking of an operating HVP plant
HIGHLIGHT
Capacity study of 12/16/20 KL reactor options
HIGHLIGHT
New 16 KL glass-lined reactor line (GMM Pfaudler)
HIGHLIGHT
Automated acid/caustic dosing + HCl scrubber + heat recovery
HIGHLIGHT
Designed to cut batch cycle 36 -> 20 hrs and ~triple capacity
HIGHLIGHT
End-to-end: assessment
HIGHLIGHT
PM and construction supervision
OPPORTUNITY → SOLUTION → OUTCOME
Opportunity. Nutriti's existing HVP line - two glass-lined reactors and a single filter press - was bottlenecked by a 36-hour batch cycle, manual filtration, yield loss and uncontrolled HCl fumes, and could not meet FY26-27 demand for hydrolysed vegetable protein. The challenge was to expand capacity within an existing, operating building and a defined budget.
Solution. PMG carried out a detailed factory assessment, modelled 12/16/20 KL reactor options against demand and the building footprint, and engineered a new 16 KL glass-lined reactor line - process block diagrams, plant layout, P&IDs, URS and BOQs - then ran vendor qualification and procurement support across the reactor, filter press, tanks, pumps, flow meters and scrubber, into project management and construction supervision.
Outcome. The selected 16 KL line is designed to roughly triple annual HVP capacity (to ~3,980 MT/yr) and cut the batch cycle from 36 to about 20 hours, while automated dosing, an HCl scrubber and heat/condensate recovery close the safety, emissions and yield gaps of the original line.
KEY CHALLENGES
Expanding capacity inside an existing
Working within fixed building footprint and budget constraints
yield-loss and manual-handling gaps
Phasing tie-ins around live production
IMPACT
1,362 -> ~3,980 MT/yr
Annual Capacity
36 -> 20 hrs
Batch Cycle (design)
7 -> ~3 hrs
Heating Time (design)
WHY PMG ON THIS PROJECT
PMG ran the project end-to-end on a live, space-constrained brownfield site - from a data-driven factory assessment that quantified every bottleneck in the existing 36-hour batch cycle, through capacity modelling of 12/16/20 KL reactor options, to a fully engineered new 16 KL glass-lined reactor line. The 16 KL reactor was selected as the best fit for required throughput, the existing building envelope and budget, and the design adds automated acid/caustic dosing, an HCl scrubber and heat/condensate recovery that the original line lacked.
FAQ
What was the scope of this project?
PMG is the end-to-end engineering consultant for Nutriti's brownfield expansion of its Hydrolysed Vegetable Protein (HVP) plant - covering the factory assessment, process design and P&IDs, equipment specification and BOQs, vendor qualification and procurement support, and project management through construction supervision of a new 16 KL glass-lined reactor line.
What is the production capacity of this facility?
The existing 12 KL reactor line produced about 1,362 MT/yr of HVP. The new 16 KL glass-lined reactor line is designed to lift combined annual capacity to roughly 3,980 MT/yr.
Why was a 16 KL glass-lined reactor selected?
After a capacity study of 12, 16 and 20 KL options, the 16 KL GLR was chosen as the best fit for the required throughput within the existing building footprint and the client's budget.
What did the factory assessment find?
It mapped a 36-hour batch cycle on the existing 12 KL reactor and ranked the top bottlenecks - slow heating and cooling, manual filtration and cake handling, yield loss from no cake washing, and uncontrolled HCl fumes.
What does the new line add?
A new 16 KL glass-lined reactor with buffer and storage tanks, an upgraded filter press, automated acid/caustic dosing with mass-flow metering, an HCl scrubber and heat/condensate recovery - roughly tripling annual HVP capacity.
What was PMG's role?
End-to-end engineering consultant: factory assessment, process design and P&IDs, equipment specification and BOQs, vendor qualification and procurement support, project management and construction supervision.
