We are the leaders in design and construction for the food and beverage industry. Engineers and builders tackling beverage plant design must follow strict guidelines and requirements at every step along the way.
We’re here to make that easy. Our core value is simple: ROI. Every decision across the project is measured against the return it delivers, and that’s where Hygienic Manufacturing Solutions comes in — we help you optimize for your ROI goals.
There are a number of primary goals for beverage facilities. ROI is at the center. But other critical pieces play into that.
Hygienic design and product safety dramatically impact the amount of usable end product that is produced. An aggressive, yet flexible layout design allows for peak capacity and repurposing of the beverage line for contract manufacturing (co-packing). Optimizing for uptime and minimizing downtime is another key area that impacts revenue.
And then the final piece is the staff that runs each facility. How much should the facility be automated, and how much staff should be involved, is a piece we can help answer. We are also experts at helping you build SOPs for your new facility so you can hit the ground running.
Each piece predicts the ROI. That’s where Hygienic Manufacturing Solutions comes in. We help you optimize for your ROI goals.
Breweries, dairies, distilleries, sports drinks, and bottling companies form the core of our beverage consultations. Health drinks are on an uptrend right now, and show no signs of slowing.
We work with both companies that are starting off, as well as large corporations that are optimizing an existing manufacturing plant.
Breweries, dairies, distilleries, sports drinks, and bottling companies form the core of our beverage consultations. Health drinks are on an uptrend right now, and show no signs of slowing.
We work with both companies that are starting off, as well as large corporations that are optimizing an existing manufacturing plant.
Pertinent areas of focus include pre-capital feasibility and ROI studies, site selection, and a utilities assessment. In an existing facility, site selection shifts to organization and layout studies to ensure that employee flow and process isn’t negatively impacted by expanded capability.
Often, companies have solved the above-ground work by the time they reach out to us, and then our focus is on the process flow and equipment list. Mapping the process and personnel flows, sizing rooms for hygienic segregation, creating all P&IDs and MEP schematics, and producing the equipment foundations and anchoring details will fall under these phases.
Automations are inserted everywhere it is cost-effective, creating factories that are literally “run by AI”.
Finally, we look at the packaging process and warehousing concepts to round out the build.
Before the construction phase begins, models for prefabrication and design are imperative. This step involves building the initial process, running the clash detection with MEP models, exporting fabrication-ready models to be used for prefabrication, and then also maintaining a digital twin for the purpose of commissioning.
Typically, this also includes functional prototype drawings such as conceptual floor plans, process flow diagrams, process throughput overviews, and other various drawings. The purpose of this is to validate as much of the unknown conditions as possible without wasting time or money on builds that haven’t done due diligence.
Food safety, sanitation, and compliance are top priorities. When planning for the construction of a beverage manufacturing plant, the design and construction firm will pinpoint all HACCP zones and critical control points, coordinate layouts with FSMA and local regulations, determine sanitation schedules and validation protocols, and then implement traceability and recall systems.
We are your one-stop source for equipment. Often, facilities like to repurpose equipment. Done correctly, used equipment can save significant costs.
The key issue is compatibility. Our engineers can source used equipment while ensuring compatibility between units. We also provide domestic and overseas sourcing of equipment.
And for the facilities that need the absolute best, equipment made in the EU or the United States tends to be the most reliable for 30-plus years of service.
This stage will involve preparing the commissioning and IQ/OQ/PQ plans and the performance of all site acceptance testing for systems. We will provide operator and maintenance training, and validated documentation and SOPs will be provided.
There are major cost drivers that occur during each project phase, and a sample timeline according to project size can be provided to highlight these factors.
For new builds, we often approach a year or more of build time, while retrofits can often be done in a matter of weeks or months.
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HACCP, SQF & regulatory-aligned from day one.
We modernize old factories or design from scratch.
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