VMS has decades of experience designing a wide spectrum of Industiral Construction and manufacturing facilities. We have designed plants and factories for auto component, glass, ceramic, pharmaceutical, food processing, agro, engineering, sugar, special economic zones (SEZs), etc. We provide energy and resource efficient design, which meets the Owner’s functional and budgetary requirements.
Special Economic Zone (SEZ)
Suzlon GroupVadodara, Gujarat
Master Plan & Infrastructure development for the SEZ spread across 485 acres. A modular approach was adopted to plan this SEZ. This resulted in optimising land use and efficient implementation of infrastructure components, while minimising initial investment. Such measures enhanced the commercial viability of the project. Modern infrastructure deployed in this project, consists of over 15km of roads, an electrical load of 40 MVA including EHV switchyard, Rain water harvesting, Water supply network, social infrastructure amongst other components. A creek running through the site was advantageously used for storm water management.
Calcutta Leather Complex
Govt. of West BengalKolkata
Spread over an area of 1100 acres the CLC is the largest integrated industrial complex for the leather industry.VMS designed the Master plan and development of entire external infrastructure including utility buildings. Over 3.5 million m3 of earthwork, 50 km of water distribution network, 30 MLD water supply, 50 km storm water drainage, 6 km internal canals, 45 km of Roads, 50 km of effluent collection network, effluent and sewage pumping stations, etc. were involved in this project. The Master Plan is designed to ensure optimal land utilisation, which was an important criterion for the BOT developer. Innovative features like large water bodies & canals were created within the complex to store sufficient water to last for 30 days. This fulfills the water dependent industry’s needs, while simultaneously getting cheap earth from the site for land filling. The canals dramatically reduce transportation costs of water & work as a low cost fire protection system. Satellite images were used to verify adequacy of ground water to sustain the complex’s long term water requirements.
Spread across 75 acres, the Agri Park houses grain storage facilities, a distillery Plant, Bottling Plant & a Brewery. Captive Power generation has been proposed along with external infrastructure like roads, ETP, Power & water distribution and Storm drainage. The Master Plan along with the road network, efficiently fulfils the statutory requirements of separating different production units. A controlled zone was also planned keeping in view the legal required for customs and excise. The Bottling & Brewery plants are designed with high standards for Food grade hygiene. The design complies with stringent standards of fire safety and effluent treatment.
Auto Component Factory
JBM AutoTata Nano Vendor Park, Sanand, Gujarat
Design for the Press Shop & Weld Shop, producing parts of the Tata Nano car. The Press shop is equipped with presses up to 1200 ton capacity & a 30 ton capacity EOT crane. The total built up area is 7,800 m2. A high level of economy was achieve in design & this was benchmarked by TATA Motors for similar projects in future. The Welding line is suspended from the roof, providing efficient usage of zero level space in the plant.
Auto Component Factory
Yanfeng VisteonSanand, Gujarat
Design of a plastic injection moulding facility at the Ford Vendor Park in Sanand. The built up area is 10,275 m2. VMS worked collaboratively with the client’s Global Facilities team from China. The standards practiced by the client were customised to align with the Indian codes as well as the Indian construction industry practices.
Auto Component Factory
Cosma InternationalSanand, Gujarat
Design of a greenfield manufacturing facility assembling chassis and BIW for Ford Motors. Plot size 35,000 m2 ndBuiltup area 15,000 m2. The Plant houses robotic weld lines and warehousing. The Ford Motors’ global design parameters were followed for the electrical systems, HVAC system as well as the steel super structure.
Mining Equipment Facility
Metso MineralsAlwar, Rajasthan
Large scale industrial development for the multi-national to establish its manufacturing base in India. This project makes pumps and crushing equipment. The Plot expands across 80 acres with a built area of over 30,000 m2 . Power requirement is 5 MW. The infrastructure developed, complies with the international best practices for an extremely efficient production facility. Rain water harvesting support the plant located at a dry and hot region. Ventilation for the plant buildings, re-cycling of the treated sewage, etc. were given lot of importance.
Supercritical Turbine Generator Factory
Alstom Bharat ForgeSanand, Gujarat
Design of a manufacturing unit for supercritical turbine generators in the 300-800 MW range at Sanand. The Project involves managing heavy loads on buildings and foundations. Heaviest gantry was of 500 ton. Floor loads were up to 35 ton per square meter. Layout and circulation were designed to accommodate oversized components which were required to be transported using 32 wheeler trailer. The Facility aims for a LEED Gold rating for energy efficient and sustainable design. VMS used the building information modeling (BIM) to resolved critical conflict between the building and heavy equipment foundations. As a result, the client was able to place equipment closer to the building’s periphery. This enabled increase in the gangway width and consequently improved operations. Construction permit was secured by VMS in a very short time.
Sacmi EngineeringSanand, Gujarat
Design of the manufacturing facility making ceramic machinery, plastic injection moulds and beverages machinery. The plot area is 51,000 m2 with the built up area of around 8,000 m2. The plant deploys a heavy crane of 100 ton. Value engineering for each aspect of the design was carried out to deliver an economic & cost effective project.
Shanghai HighlyChangodar, Gujarat
Design of the factory to make compressors for A.C. units for the Chinese MNC. To expedite commissioning, an existing unit was rented & converted into a modern production facility. With a deep understanding of the processes and the technological requirements VMS tailored engineering designs produced in China to suit Indian construction practices, materials & statutory requirements.
Roxul RockwoolDahej, Gujarat
Design of a warehouse & storage yard for an existing Plant for the American multi-national. The The Project was completed within a strict time and budget. Special attention was given to the safety aspects, as the work was carried out in a running Plant. VMS also handled Construction management for the project.
Hitachi Hi Rel Power ElectronicsSanand, Gujarat
The Medium Voltage Drive manufacturing unit was designed strictly to Hitachi's standards of dust and temperature control. The Plant building is centrally air conditioned with 5 micron filters and is equipped with anti static flooring (1 x 105ohms - 1 x 108 ohms). The testing facility was designed & established with a re-generative capacity to test MV Drives. A study of Hitachi's Plant at Japan gave real insights on requirements related to environmental control, flooring spec, utilities & safety. VMS’s result oriented involvement in Construction management helped to complete the project on schedule, within the budget, including the validation of the completed Plant by Hitachi's Japan team & 3rd party inspections carried by Kajima India. The facility uses jet nozzles for air conditioning resulting in high savings in energy consumption.
Design of a factory for producing high-end sanitary products like washbasins, urinals and WCs. The site sprawls across an area of 1,70,000 m2. The production building is 96m wide x 306m long. Total built area is 35,000 m2. Time saving solutions were implemented from the conceptual stage to complete the project on time, within budget. The low lying plot necessitated large amount of earthwork. Under-reamed piles ensured faster construction under this scenario. Roof ventilators provide natural ventilation to the plant. The plant has extensive landscaping. Special water proofing treatment was given to the sensitive furnace foundations.
Hitachi Home & LifeKadi, Gujarat
Designing a Plant manufacturing Industrial Air conditioning units. A single shed of 35,000 m2 built up area is used. The Fast track Project was constructed & commissioned in a period of mere 9 months. The visually pleasing 175 m x 200 m shed is designed to minimize artificial lighting by using ample skylights. The challenge to efficiently connecting the new Plant to the existing Plant was resolved successfully.
90 KLPD Distillery
Uflex IndustriesAligarh, U.P.
Design for a stand alone Distillery with a 90 KLPD capacity including a Bottling plant & captive Power generation. The 45 m high distillation building is equipped with several intermediate steel platforms. The Tank foundations for Molasses storage & Fermentors span across 6000 m2 area, adhering to necessary hygiene standards. A thorough understanding of the processes & material movements helped VMS to evolve layout of buildings & roads for extremely efficient operations.
100 KLPD Distillery
Oudh SugarHargaon, U.P.
Foundation design for the Distillation building, Evaporator, Ware House, and 1,00,000 quintel molasses tank. Power house having 2.5 MW turbine was also designed.
Food Processing Plant
Design of a factory producing noodles, candies and other products for the Indonesian food giant Mayora Group. The site is spread across 85,000 m2. Built up area is approx 42,000 m2. Multiple products will be produced simultaneously within the facility. This was a first time scenario for Inbisco and there were concerns about product environment mixing into one another. Cost effective full height partitions were designed to contain and segregate individual products while maintaining required hygiene and GMP standards.
Potato Processing Plant
McCain FoodsMehsana, Gujarat
McCain is a Canada based global company and world’s largest producer of French Fries and other frozen food products. Looking to the potential of high quality potato supply in the region, it wanted to setup a plant in North Gujarat. VMS was engaged early on, initially taking care of the Owner’s interest on a design-build (turnkey) project. Later, engineering and design services were provided including converting a flake line into a specialty product line. As a trusted advisor, VMS has guided McCain throughout various capex in the history of this plant enabling McCain to adapt their global plant engineering and construction processes locally in an optimum manner.
Dwarikesh SugarBijnor, U.P.
Design for a large, modern Sugar Complex with 7,500 TCD capacity co-generating 36 MW of power. VMS designed heavy equipment foundations for Cane crushing & Milling machiery, High Pressure boilers, 24 MW TG set, Cooling towers, etc. Additionally, large storage godowns for Sugar bags, Tank foundations & 132 KV Switch yard were designed. A deep understanding of the manufacturing process enabled prioritising design & construction process - helping the client to start production earlier.
Fiji Sugar CorpIsland of Fiji
Massive up gradation of the state-owned factories of Fiji Sugar Corporation at Lautoka , Rarawai and Labasa under guidance of Sugar Technology Mission - India, providing technical expertise & machinery. The foundation of very heavy sugar machineries was designed braving adverse conditions like existing foundations in the vicinity, poor soil conditions and extreme weather.In addition VMS designed the foundation of large capacity injection pumps in river at two factories. The steel structures were designed using Australian sections.
Glass Tube Factory
Gerreshiemer GlassKosamba, Gujarat
Design of a 5,300 m2 factory making glass tubes. The facility is bird proof, and has a clean environment. It confirms to the stringent requirements of Pharma industry.
Figured Glass Plant
A new plant was built adjacent to the Old plant on an area spanning 10,000 m2. The plot is spread over 35 acres. The unit manufacturers Figured glass for Residential and Industrial use. The building has an elegant PEB structure. To save time on construction, independent analysis of the structure was done before the PEB was ordered. The goal was to finish the foundation before monsoon. The machine floor has been kept separate from the building to avoid the effect of displacement due to wind.
Frit Manufacturing Plant
Endeka CeramicsJhagadia, Gujarat
Endeka is a global leader in the ceramic industry. The unit was set up to manufacture glass frits, used in coating vitrified tiles. The production facility has several pneumatically and computer controlled steel silos for storing raw materials. The plant also has several furnaces for melting and quenching the raw material. Due to the onset of monsoon, black and sticky soil made construction very difficult. VMS proposed lime stabilisation of the soil as a cost effective solution. The processes plant was shipped from Italy. VMS also helped extensively with mechanical, electrical and instrumentation design and customisation to adopt it locally.
Warehouse & Mixing Facility
Colorobbia ChemicalsSanand, Gujarat
Colorobbia is an integrated chemical group active in 15 countries, specialising in material research, mining, transformation, production and marketing for the ceramic industry. In addition to design of the factory, VMS also helped Colorobbia to secure timely permits to start construction and phasing of the total investment.
Readymade Garment Manufacturing Plant
D.R. GarmentsPorbandar, Gujarat
Greenfield manufacturing facility for a NRI group supplying readymade garments to UK's major Garment Retailers. The plant spans over an area of 10,000 m2. A three storied Office Building, was also designed using Structural steel. The initial Concept was developed by the Client in the UK. The project was then awarded on turnkey basis to the Ahmedabad based Contractor JMC Projects - with the support of VMS at the bidding stage. The work included converting the concept to suit Indian conditions, available materials & Construction technology. Subsequently, detail engineering was carried out executing the initial concept successfully, within the budget.
Dhruv CottonJasdan (Rajkot)
Design of a 27,000 spindle unit spread over 11,000 m2. The spining mill was developed in an exsisting ginning facility. Being a fast track project, critical part of the project were completed in just 7 months. The structure is designed keeping in mind the requirement of return Air trenches in a spinning mill. Over 3,000 m of return air trenches were implemented in the unit.
JBM AT FORD MOTORS
JBM Auto Systems Pvt. Ltd.Sanand, Gujarat
VMS designed a plant which supplies auto-ancillary parts to Ford Motors at Sanand. The plant constitutes 5 press lines having more than 20 presses ranging from 400T to 800T. Of the total area of 61,000 sq. m, the plant building comprises 14,000 sq. m and the other 2,500 sq. m is occupied by a two- storey service building. The clients' alteration in the project requirements at a later stage of the design was spontaneously integrated and incorporated at the earliest. The plant boasts an underground conveyor tunnel network.
Magna Closure Automotive Pvt. Ltd.Sanand, Gujarat
Magna Closure Automotive Pvt. Ltd. will develop and manufacture high quality complete seating systems, mechanism and hardware solutions, specialty mechanism solutions, seat structures as well as foam and trim products for Ford. The 20,250 sq. m constitutes the civil, electrical, plumbing, fire- fighting system, compressor and piping in the main plant and its ancillary buildings. The factory is a PEB structure. All of the building’s services are designed as per FM Global design requirements. The plant building and other ancillary building are designed to provide a good amount of natural daylighting reducing energy costs.
PANAM ENGINEERS LTD.
Panam Industries Pvt. Ltd.Prantij, Gujarat
Panam Engineers Ltd. is a manufacturing unit for tube fittings and instrumentation valves in SS. While designing this project, consideration was taken to provide no secondary beam in the complete span of 100 m. This helped the rooms to look more spacious and saved a lot of construction time. Natural daylighting and good ventilation in the plant and ancillary buildings have been well taken care of. Also, the overall master layout has been planned keeping in mind the basics of Vaastu requirements.