Petfood Production Facility Master Plan

Project Overview

A Petfood Manufacturer in Peru engaged 1 Solution Group to develop a comprehensive master plan to support the expansion and optimization of its production facility in Peru. The project focused on improving operational efficiency, maximizing available space, and defining the process infrastructure needed to support future growth.

Through detailed engineering analysis and layout planning, the project established a clear roadmap for scaling production while maintaining efficient workflows and cost-effective utility usage.

Client Goals

The client sought to create a strategic facility master plan that would support increased production capacity while improving the overall operational efficiency of the plant. Key objectives included:

• Developing a master plan to improve plant operations and facility layout
• Optimizing available space to maximize production capacity
• Defining the process required to manufacture key products, including standard and specialized product lines
• Planning infrastructure capable of supporting a projected capacity of 55,000 tons per month

The client required a practical, scalable plan that would guide future facility investments and operational improvements.

Scope of Work

1SG provided a range of engineering and planning services to support the facility optimization effort. Process and Equipment Planning The team developed a comprehensive equipment process flow design, incorporating:

• Four extrusion lines
• Supporting processing and handling systems

These flow diagrams established the foundation for efficient production sequencing and material movement throughout the plant. 3D Layout and Space Optimization Using advanced modeling techniques, the team conducted a 3D equipment layout optimization analysis. This analysis ensured that:

• Equipment placement maximized production efficiency
• Space utilization supported future expansion
• Workflows minimized bottlenecks and material handling challenges

Utility Planning

A preliminary utility usage analysis was completed to estimate the plant's future utility requirements, ensuring the facility infrastructure could support increased production.

Cost Estimation

The project included an Order of Magnitude Cost Estimate (OMCE) using factored cost methodology. This estimate provided the client with a high-level investment forecast for implementing the master plan and installing the required equipment.

Equipment Sizing and Specifications

1SG also developed preliminary equipment sizing and specifications, helping define the technical requirements for future procurement and installation.

Results & Client Benefits

The project successfully delivered a clear roadmap for expanding and optimizing the facility. The client confirmed that the project met or exceeded expectations across several key areas, including:

• Overall project execution
• Quality and usefulness of deliverables
• Professionalism and expertise of the 1SG team
• Value provided through engineering analysis and planning

The deliverables provided the client with a strong foundation for decision-making, helping define the next steps for facility expansion and investment. Most importantly, the master plan clarified how the facility can achieve its target capacity of 55,000 tons per month while maintaining efficient operations and scalable infrastructure.