Project
Hydrolyzed Vegetable Protein Manufacturing
PMG engineered Nutriti's brownfield HVP plant upgrade in Gujarat - factory assessment, a new 16 KL glass-lined reactor line, procurement and project
Opportunité
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.
Résultat
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.
Normes et conformité
Points forts du projet
Brownfield debottlenecking of an operating HVP plant
Capacity study of 12/16/20 KL reactor options
New 16 KL glass-lined reactor line (GMM Pfaudler)
Automated acid/caustic dosing + HCl scrubber + heat recovery
Designed to cut batch cycle 36 -> 20 hrs and ~triple capacity
End-to-end: assessment
engineering
procurement
PM and construction supervision
Principaux défis
Expanding capacity inside an existing
operating building
Working within fixed building footprint and budget constraints
Eliminating HCl-fume
yield-loss and manual-handling gaps
Phasing tie-ins around live production
Résultats en matière de durabilité
Impact (avant → après)
Pourquoi PMG a été choisi
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.
