Snacks Factory Reorganization for Expansion Project

Opportunity. The project involved relocating an existing snacks manufacturing line to a new location within a compressed timeline. It required meticulous planning, coordination, design, and project management to achieve three main objectives: (a) preparing the new location for a seamless plug-and-play setup, (b) fast-tracking the safe dismantling and relocation of the existing setup, and (c) ensuring commissioning with a vertical start-up. The key challenges included handling the dismantling, shifting, installation, and commissioning of an older production line, as well as the timely procurement of numerous minor items and services essential to the process. Despite these complexities, the project was executed efficiently, ensuring a smooth transition and minimal disruption to operations.

Solution. The scope of work included a detailed study of the existing Flavorite Fryer and its related installations to plan for its dismantling, relocation, and re-commissioning. This involved preparing a comprehensive Bill of Quantities (BOQ) for the necessary materials and services, while ensuring timely procurement in close coordination with Haldiram’s purchase team. Additionally, our team provided on-site supervision throughout the installation and commissioning phases, ensuring that the relocated fryer was operational and meeting production requirements promptly and efficiently.

Outcome. A process line involves not only the main equipment but also various interconnected industrial services, including steam, chilled water, compressed air, effluent management, water supply, electricity, HVAC, and fire protection systems. Relocating an existing, especially older, setup is a complex challenge, as all systems must work in harmony to deliver the desired outcomes. Our team of process, mechanical, electrical, and food safety engineers conducted an in-depth assessment and developed a comprehensive plan, allowing us to execute all tasks simultaneously rather than sequentially. This approach, which would have otherwise taken 2-3 weeks, enabled us to complete the relocation and resume production within just 2 days. Such efficiency was achieved through the team's foresight, ownership, and thorough preparation, ensuring everything was ready before the shutdown.