Opportunity
Haldirams, a renowned industry leader in traditional snacks and sweets, aimed to establish a new, highly automated production line for Aalu Bhujia. The project involved key equipment suppliers such as Flavorite, Vemag, Diosna, and CEPI, among others. To meet both export and domestic demands, the facility was designed to adhere to global standards in food safety and hygienic engineering, prompting a comprehensive re-evaluation of every aspect of the project. Effective coordination and seamless integration between international and local suppliers and service providers were critical to ensuring the project's success.
Solution
Our services for Haldiram's Aloo Bhujia production line project encompassed a comprehensive range of design and supervisory tasks. These included the relocation of the existing production line, creating a detailed Floor Master Plan with building and equipment layouts, and preparing elevations for all sections. We provided equipment design, specifications, and Bills of Quantities (BOQ) for essential industrial services such as compressed air, water, electricity, HVAC, fire protection, and drainage. Additionally, we conducted a techno-commercial evaluation of suppliers and contractors, produced Good for Construction (GFC) drawings across civil, mechanical, electrical, and process disciplines, and oversaw the installation and commissioning of the equipment. Our approach also introduced innovative ideas to help Haldiram meet global standards in food safety and hygienic engineering.
Outcome
Fried snacks are highly vulnerable to fungal contamination due to poor environmental controls between the fryer and the packing machine, leading to unacceptable water activity levels. Moreover, the concept of foreign body prevention is often not well integrated with both dry and wet raw materials. Many companies still rely on metal detectors or X-ray machines as the primary quality assurance measures. Individual batch processes, such as potato boiling and dough making, are often linked with unregulated manual operations, such as mixing, blending, and feeding to the fryer, which significantly increases the risk of contamination. Additionally, a lack of zoning and inadequate procedural controls on workers contributes to cross-contamination and compromises food safety systems. To address these challenges, the PMG team redefined the project objectives and convinced the client's management of the importance of a detailed approach to meet stringent food safety standards and build a food-safe facility. For instance, instead of concealed cables, we opted for mesh-type cable trays that are fully accessible and cleanable, eliminating foreign body risks. We also recommended water-based HVAC systems for temperature and humidity control in post-fryer zones to avoid the humidity increases associated with air washers. In place of traditional GI ducting, we used polyester ducts for supply air and return grills for return air, with F7 filtration to prevent microbial contamination. We also introduced polyurethane flooring with coving, water-seal floor traps, and other hygienic engineering measures. The layout was optimized to ensure efficient use of space, with 24 packing machines feeding directly from the fryer, along with sufficient space for secondary packing. The project was successfully completed within the stipulated time frame.
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