Food manufacturing: Sustainability, process and GMP design
McCormick, a global flavours leader, produces seasoning blends, flour and spices for retail, commercial and industrial markets. Their new manufacturing development near Bangkok will serve the growing South East Asian market. Production includes both liquid and dry powder and pepper processes.
To cater for growing demand and provide a single manufacturing base for South East Asia, McCormick embarked on this new three storey manufacturing development. The project involved the relocation of manufacturing capacity from the company’s existing Thailand plant and transfer of lines from existing facilities in Singapore and Australia.
The finished products and manufacturing processes include both liquid and dry (primarily powder) lines. The dry process includes blending, milling, sifting, packaging and case packing operations. The liquid process includes mixing, filling and packaging operations.
PM Group provided full engineering design services and site technical support during construction. Our Singapore based team of process experts designed and delivered a Best-In-Class process facility. The building’s innovative design solution allows for easy expansion and integration of future requirements.
Lean principles were utilized in developing the site masterplan, facility layout, utility spine and energy efficient features. Lean design was an integral aspect of this project. Lean workshops focused on optimizing the individual line layouts as well as the integration of all lines into a coordinated lean facility layout. The process areas also incorporates modular segregation for the manufacturing of allergens and non-allergens.
Working with our Bangkok based partner, Meinhardt, the project team combined specialist food manufacturing expertise with local market knowledge. PM Group and Meinhardt also managed the local permitting and the LEED certification processes. The facility has been certified to LEED Silver (v4.1) standard. Its energy efficient features include 100% LED Lights and 100% condensate recovery for energy and water.