Plant Head - OEM

Plant Head - Mehsana - Gujrat

Develop detailed layout incorporating :

- Raw material reception area

- Washing, peeling, slicing zones

- Blanching and dewatering lines

- Continuous fryer (temperature control, oil circulation systems)

- Seasoning and flavoring drums

- Packaging lines (FFS machines, nitrogen flushing)

- Cold storage for raw potatoes

- Finished goods warehouse

- Define hygienic zoning: Low-risk, high-risk, storage zones (per ISO 22000 and HACCP norms)

- Implement unidirectional flow of material and personnel

2. Equipment Specification & Sourcing

Finalize specs and procure:

- Raw Material Handling: Elevators, de-dusters, sorting conveyors

- Processing Line: Automatic peelers, high-speed slicers

- Frying System: Continuous frying line with oil filtration, temperature control (180-200- C), oil life monitoring

- Seasoning: Drum coating units with inline oil/flavour spray systems

- Packing: Multi-head weighers, VFFS machines, nitrogen injectors, metal detectors

- Control Systems: PLC/SCADA-based automation, HMI screens, batch tracking

3. Utility Design & Engineering

- Compressed Air System: Dry, oil-free air for pneumatic controls

- Boiler/Steam Generation: For blanching

- Water Treatment Plant: RO + UV filtration (E.g.1000-5000 LPH based on capacity)

- Effluent Treatment Plant (ETP): To treat wastewater with potato starch/oil

Electrical Systems:

- HT/LT Panels

- Backup Generator (DG Set sizing as per total connected load)

- Power Distribution to Machines

Ventilation & HVAC:

- Positive pressure in production zones

- Dehumidifiers for seasoning/packing area

Fire Safety & Building Codes:

- Fire hydrants, extinguishers, fire alarms, smoke detectors as per NFPA/IS standards

4. Capacity & Throughput Planning

Plan and set up for:

- Input: 1-5 Tons/hr of raw potatoes

- Output: 300-1000 kg/hr of finished wafers (adjustable)

- Downtime minimization strategy (OEE > 85%)

- Plan for future scalability in line modular design

5. Regulatory & Food Safety Compliance

- FSSAI registration, layout approvals, and license coordination

- Implement hygiene and sanitation protocols: SS drain channels, foot dips, hand wash stations

- Integrate traceability system (barcoding, batch-wise tracking)

- Build Quality Control Lab: Microbial testing, oil degradation testing (TPM), moisture, etc.

6. Project Management

- Prepare BOQs, RFQs, vendor finalization through technical comparison (TCO-based)

- Track construction timelines, machine delivery, installation, SAT & FAT

- Liaison with civil/electrical contractors, automation partners

- Prepare & execute project Gantt charts (Primavera/MS Project preferred)

7. Manpower Planning & Training

- Define org structure: Operators, maintenance, QA/QC, logistics

- Create SOPs for all equipment

- Oversee initial recruitment, training, and SOP induction

- Experienced in FAT/SAT protocols for OEM machinery