50 KLPD Aseptic Juice Factory - Utilities Design

Opportunity. The project involved the construction of a state-of-the-art juice factory with a capacity of 16 TPH, producing 200 mL and 1000 mL SKUs, over a 12-month timeline, encompassing civil works, equipment installation, and commissioning. The goal was to partner with top-tier suppliers for plant and machinery, with Tetrapak selected to supply the process equipment. The PMG team was entrusted with the design and execution supervision of industrial services, including a high-capacity water treatment plant, boiler upgrades, steam and compressed air systems, effluent treatment, electrical power and lighting systems, as well as the pipe bridge and pipelines. The design and installation of these services posed significant challenges, particularly as the project required upgrading the existing utilities, such as the biomass boiler and effluent treatment plant, while maintaining uninterrupted operations at the existing food park.

Solution. The Basic and Detailed Design of Industrial Services for the Fazilka Mega Food Park included a comprehensive assessment and upgrade of existing utilities infrastructure, such as buildings, boilers, refrigeration plants, electrical systems, effluent treatment, cold storage, and warehouses. The scope of work involved developing key engineering documents, including flowsheets, P&ID, equipment layouts, elevations, and piping and electrical distribution plans for a thorough condition assessment. The project also included the design and planning of necessary upgrades for existing utilities and the creation of new utility systems, such as the Water Treatment Plant, Air Compressors, Electrical LT, Transformers, and Diesel Generators, along with the design of utility distribution pipe-racks and piping. Active collaboration with all stakeholders was key to ensuring quality and alignment at every stage. User Requirement Specifications (URS) were developed for each component, complete with a Bill of Quantities (BOQ), performance parameters, and expectations. The project also involved floating inquiries, evaluating offers from suppliers and contractors, and providing support to the Client’s purchase team to ensure timely purchase orders and advances. The review and approval of shop drawings from each supplier were meticulously handled, with all designs integrated into a master drawing to ensure harmony and avoid clashes. Good for Construction (GFC) drawings were issued for execution, and factory visits to key suppliers ensured proactive quality checks and timeline tracking. Additionally, support was provided for Factory Acceptance Tests (FAT) before dispatch and Site Acceptance Tests (SAT) to verify performance parameters before final payments were released.