FOOD AND BEVERAGE INDUSTRY OVERVIEW

The Food and Beverage Industry includes all the companies involved in transforming raw agricultural goods into consumer food products.

The overall industry supply chain includes food processing, packaging, and distribution. It does not cover raw food production, which falls into the closely related agriculture
industry.

This industry includes fresh food, packaged food, and beverages (both alcoholic and non-alcoholic). From food sold at the grocery store to cooked meals served at restaurants,
institutions, and events, this industry serves a huge variety of retail outlets.

FOOD AND BEVERAGE INDUSTRY

PAIN POINTS
The food and beverage industry is tasked with solving some unique business challenges:

● A time-sensitive supply chain where the product can go bad fast. This reality means food
companies are always on a schedule, need to plan for specialized storage and transportation,
and have to practice careful inventory control.
● A manufacturing production environment with unique demands for hygiene and safe food
handling. This imperative includes everything from exhaustive equipment cleaning
requirements to tight controls and potential allergens.
● A highly regulated industry that needs to carefully ensure production practices are up to
code.
● A tendency toward price-sensitive products where every margin matters.
Organic industrial growth rate related assumptions

Industrial Sectors Description of the Assumptions

• 13% annual growth from 2012 to 2018
• 10% annual growth in 2019
Textiles & RMG
• 8% annual growth from 2028 to 2043

• 8.5% annual growth from 2012 to 2019

• 10% annual growth from 2028 to 2030
Food & Beverages
• 9% annual growth from 2031 to 2043

• 8% annual growth from 2012 to 2019

• 10% annual growth from 2028 to 2031
Agro based products
• 8% annual growth from 2022 to 2045
Industrial space uptake- Base Scenario (figures in acres) - cumulative

Industries 2025 2026 2027 2028 2029 2030 2031 2032 2033 2034 2035 2036 2037 2038 2039 2040

Textiles and
23 57 97 135 180 217 252 293 337 397 465 543 630 706 706 706
RMG

Food and
7 17 29 42 57 70 81 94 108 128 150 176 205 231 231 231
Beverages

Agro based
0 1 1 2 3 3 4 4 5 6 6 7 9 10 10 10
products

Base scenario

assumes Business-as-Usual situation for the overall economic

condition of the country and the influence region
Compatibility Mapping

Sector` Access to Backward Access to Factors of Production

and Forward Linkage

Access to Access to Land Air Water Availability Availability Availability Availability Access to
Raw Markets Connectivity Connectivity Connectivity of Power of Water of Gas of Water
Material manpower Front

Features prevailing at proposed EZ Easy to Multiple Multiple Sufficient Water Available in Semiskilled/ Not
access modes of modes of power source the vicinity Unskilled immediate
transport transport available available in available;
required required vicinity limited
skilled

Food & High High Moderately Moderate Moderately Moderate Moderate Moderate Moderate Moderately
Beverages High High Low

Rationale for selection

● Paddy, jute, wheat, mustard, sugarcane, onion, garlic, potato, sweet potato, chilly and groundnut are the major crops in the district and nearby areas
● Mango, papaya, blackberry, guava, coconut, palm, banana, and olive are the major fruits produced in the district and nearby areas. Using these fruits, and
other agriculture, significant number of Food & Beverages products can be manufactures
● Water is available in the close proximity of the proposed EZ, and other utilities such as power are also available in the district.
● There is significant demand for Food & Beverages products in Dhaka, and also Mymensingh and Rajshahi. These products can also be
● exported to the north east India and Nepal and Bhutan

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 Sector Food & Beverage Sector

Fish and Shrimp Processing, Salt Processing, Fast Moving Consumer Goods
Sub-Categories Proposed (FMCG) like cake, biscuit, bread etc.

• Out of the various subcategories, demand for (i) fish and shrimp
processing, and (ii) biscuits have witnessed significant growth in the
past
• Bangladesh specializes in fish and shrimp export; Khulna and
Chittagong are the two main hubs for shrimp production. Bangladesh
exports shrimp and fish over 600 to 700 million USD every year
• Biscuit industry in Bangladesh has depicted growth of 15% YOY in the
last few years.135
Sector Overview • Agriculture and aquaculture are the main pillars behind this industry
in Bangladesh
• FMCG constitutes major part of this industry and most of the FMCG
oriented manufacturing plants are in proximity to Dhaka, Chittagong,
Khulna, and Sylhet as these are the major consumption hubs
• Water is one of the most critical ingredients for this sector
• Major players: Pran, Meghna, Abdul Monem, Olympics; this sector
has witnessed participation of a large number of medium scale players

• Started as domestic focused sector, but export is rising significantly

• Since this sector is less dependent on import and dependent on
domestic for both sourcing of input and sell of output, this sector is
poised to witness sound growth due to rising income levels and
increasing affordability.
• Demand for nutrient rich, high quality food products is increasing.
• Fish and Shrimp is a major export commodity and the demand has
been depicting an increasing trend
• Bangladeshi food & beverage exporters are exporting processed food
products to 104 countries (major destinations being Middle East,
Sector Trends
India, and other South Asian countries).
• Pran is the most prominent Food & Beverages player in the country
and it has footprints in Middle East and in India
• Meghna Group and Abdul Monem Group are the other players, which
are quickly capturing market share
• Fish and shrimp processing sector have small to large players;
whereas Food & Beverages sector is dominated by medium and large
players (some being foreign)
Food & Beverage
Sector Sector

• Land requirement depends on the capacity of the factory, type of

technology and type of sub-sector (finished goods).
• Basis primary survey, typically medium scale players require 3 to 7
acres and large players require 10 to 20 acres for a single food &
beverage manufacturing facility.
Land Requirements • For fish and shrimp processing facility, area is dependent on capacity
as there is a pond/ shrimp cultivation facility (artificially cultured
pond) attached with the processing facility.
• Following chapter delves into forecasting of industrial land
requirement for this sector

• Power requirement depends on the capacity of the factory, type of

technology and type of sub-sector (finished goods).
• For medium scale facility, power requirement can vary from 0.5 to 1.4
MVA; whereas, for a large-scale facility, power requirement may vary
Power Requirements
from 1.6 MVA to 4 MVA
• Following chapter delves into forecasting of industrial power
requirement for this sector

• Water requirement depends on the capacity of the factory, type of

technology and type of sub-sector (finished goods)
• Current practice in Bangladesh is to install deep tube-wells and
extract groundwater for industrial consumption. Permission from
GoB needs to be taken to install the pump, however, there is no
monitoring mechanism in place to check the amount of water
Water Requirements extracted
• For medium scale facility, water requirement can vary from 90 to 350
Cum/ day; whereas, for a large-scale facility, water requirement may
vary from 300 cum/ day to 600 cum/ day
• Following chapter delves into forecasting of industrial water
requirement for this sector

• Manpower requirement depends on the capacity of the factory, type

of technology and type of sub-sector (finished goods)
• For medium scale facility, typically 60 to 180 number of
manufacturing related employees are employed; whereas for a large
Employment per Factory facility, typically 200 to 500 number of manufacturing related
employees are employed in a facility
• Following chapter delves into forecasting of manpower requirement
for this sector
Site specific barriers
Major challenge that industry players faced in this sector was from the unorganized
and small-scale industries, which had localized operations and had a cost
advantage over the organized sector through evasion of taxes.

Voice on ground from stakeholder consultations

Manufacturers from this industry were positively interested in the proposed EZ in
Tangail due to the close proximity to consumer markets in Dhaka. Manufacturers
also pointed out the fact that whilst operating out of an EZ, they would ideally want
the developer to take care of all the documentation and labor issues.

Respondents opined that they have certain pre-requisites of investment. Key

pre-requisites as divulged by the
primary survey are:

• Subsidized industrial land space and utility tariffs

• Warehousing facility
• Prompt administrative procedures
• Access to concessional loans
• Corporate income tax subsidy
• Uninterrupted access to quality utility services (power, water, and gas)
• Availability of labor
• Availability of raw materials
• Access to CETP/STP
FOOD PROCESSING EQUIPMENT
This industry uses a huge variety of specialized equipment to turn raw food into food products at scale. Because there are so many different
types of food processing, the machines involved can place very different operational stresses on bearings and similar components.

Some of these machines are run almost 24/7: that’s the only way to maximize production in this high-volume industry. This means stoppages for
maintenance, critical failures, and contamination problems all represent serious threats to efficient production to meet all orders in time.

Fast freeze systems quickly take food products from room temperature to -112°F via a conveyorized tunnel. The bearings within the tunnel can’t
be accessed for lubrication. These bearings act as the belt roller supports as the food moves through the tunnel.

Food mixers utilize different polymers depending on the media being mixed.

Ovens are a huge part of many sorts of conveyorized baking, making products like tortillas, pizza crust, cookies, and bread. All of these ovens
use bearings within the oven tunnel to support the conveyor belt. These belts are traditionally made from either stainless mesh or coated
fiberglass.

FOOD PACKAGING EQUIPMENT

Can Manufacturing Equipment: from body makers and decorators to lid makers and neckers,
these complex machines have dozens of bearing locations that require high-performance
materials.

Flexible Packaging Line Equipment: these machines can handle 60,000 packages per hour
and require reliable 24/7 performance for optimal volumes.
Types of Food Processing Equipment

● Preparation
● Mechanical processing
● Heat processing
● Preservation
● Packaging
Food Preparation Equipment
Unit Operation Description
● Removes foreign matter and
contaminants—e.g., soil, oil, insects, skins,
Cleaning chemicals, etc.—from the surface of raw food
material via wet and dry cleaning processes
● Closely related to, and often precluding, sorting
processes
● Assesses several characteristics of food matter
Grading
(e.g., flavor, damage, skin color, aroma, etc.) to
determine the overall quality
● Removes inedible or undesirable material to
increase the overall quality and/or appearance
Peeling/Skinning
of the final food product
● Operates similarly to and overlaps with dry
cleaning processes
● Classifies and separates foreign matter and
Sorting contaminants from raw food material based on
a measurable physical characteristic (typically
size, shape, weight, or color)
Equipment Employed
Wet Processes
● Soak/floatation tanks (soaking)
● Spray washers (spray washing)
● Washing systems (washing)
● Sterilizers (sterilizing)
● Ultrasonic cleaners
Dry Processes
● Air classifiers
● Magnetic separators
● Screening separators
● Tungsten lights (candling)
● Image processors
● Laboratory equipment
● Pressure vessels (flash steam peeling)
● Stationary/rotating blades (knife peeling)
● Carborundum abrasive rollers/bowls (abrasion
peeling)
● Conveyors and furnaces (flame peeling)
● Sorting machinery
● Disc separators (shape sorting)
● Sieves/screens (size sorting)
● Machine vision sorting systems
● Sorting conveyors
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Mechanical Food Processing Equipment
Unit Operation Description Equipment Employed

Grinding/Crushing

● Impact mills
● Pressure mills
● Attrition mills
● Reduces the average particle size of solid food matter ● Jaw crushers
through mechanical processes involving compression, ● Roll crushers
Size Reduction shear, or impact force ● Strainers/pulpers

Cutting/Chopping

● Knives/blades
● Band saws
● Slicing machines
● Meat grinders

Extrusion

● Non-thermal extruders
● Single-screw extruders
● Twin-screw extruders
● Refrigerated extruders

Agglomeration
● Increases the average particle size of solid food matter ● Rotating pans
through mechanical processes, such as extrusion, ● Rotating drums
Size Enlargement
agglomeration, or forming ● High-speed agitators
● Tableting equipment
● Pelletizing equipment

Forming

● Bread molders
● Pie and biscuit formers
● Confectionary molders
● Enrobing machines
Mechanical Food Processing Equipment (cont.)

Unit Operation Description Equipment Employed

● Also referred to as emulsification ● Homogenizers

● Reduces the average particle size and increases the ● Emulsifiers
Homogenization
consistency of semi-solid and liquid food matter ● Colloid mills
● High shear mixers

Fluid Mixers

● Agitated tanks
● Paddle mixers
● Combines and disperses two or more components into ● Anchor mixers
one another to achieve and maintain a uniform mixture ● Turbine mixers
and/or an alteration to the functional or aesthetic
qualities of the food product (e.g., texture) Dough/Paste Mixers
Mixing ● Type of equipment depends on the form of the food ● Horizontal dough mixers
components—gas/liquid, liquid/liquid, liquid/solid, ● Sigma-blade mixers
solid/solid ● Cutter mixers

Solids Mixers

● Diffusive (passive) mixers

● Convective (active) mixers
● Drum blenders

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Heat Processing Equipment

Unit Operation Description Equipment Employed

● Similar to, and often referred interchangeably with,

roasting
● Employs heated air (heated by convection,
conduction, and radiation)—and, in some cases, Baking ovens
water vapor—to heat and produce physical and ● Direct heating ovens
chemical changes in food material, such as texture or ● Indirect heating ovens
Baking
flavor ● Batch ovens
● Assists in the preservation of food matter by ● Continuous and semi-continuous ovens
destroying microorganisms and reducing the amount
of moisture at the food surface
● Suitable for producing bread, crackers, biscuits, and
other flour- based or dough-based products

● Employs heated water or steam to reduce the

number of microorganisms and inactivate
undesirable enzymes which can cause spoilage Blanchers
● Also cleans, removes excess air from, softens, and
Blanching improves the overall quality ● Steam blanchers
● Typically follows preparation operations and ● Hot water blanchers
precedes preservation operations, such as
packaging, dehydrating, or freezing
● Suitable for fruits and vegetables

● Employs heat to remove (i.e., evaporate) water from

solid, semi-solid, or liquid food material with the
intention of producing a solid food product with Dryers
sufficiently low water content ● Convective dryers
Dehydration ● Increases the shelf life of food products due to the ● Contact (conductive) dryers
reduced water content which inhibits microbial growth ● Vacuum dryers
and enzyme activity ● Freeze dryers
● Reduces weight and volume and/or transforms the
form of the final food product

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Heat Processing Equipment (cont)
Unit Operation Description Equipment Employed

● Removes volatile solvents (typically water) from food

material by boiling to increase the concentration of
solid contents
● Increases the shelf life of food products due to the Heat exchangers
reduced water content, but also increases the rate of
chemical deterioration ● Evaporators
Evaporation ● Condensers
● Reduces the weight and volume of the final food
product ●
● Typically precedes operations, such as crystallization,
precipitation, and coagulation
● Suitable for liquid-based food products

● Employs heated (~160–180 °C) fat or oil to transfer

heat directly to food material Fryers
● Reduces moisture content, forms a surface crust ● Batch fryers
Frying
(changes texture and structure), and inactivates ● Continuous fryers
microorganisms which improves shelf life and overall
quality

● Processes food material under medium temperatures

(70–100 °C) to inactivate most enzymes and Pasteurizers
microorganisms (but not spores) which cause spoilage
● Produces food products with limited shelf lives ● In-container pasteurizers
(short-term preservation method) ● Continuous flow pasteurizers
Pasteurization
● Little to no impact to quality and characteristics beyond Heat exchangers
the shelf life
● Suitable for dairy, fruit/vegetable-based, wine, beer, ● Plate heat exchangers
and egg products ● Concentric tube heat exchangers

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Heat Processing Equipment (cont)

Unit Operation Description Equipment Employed

● Similar to, and often referred interchangeably with,

baking
● Employs heated air (heated by convection, conduction,
and radiation)—and, in some cases, water vapor—to
● Roasting machinery
heat and produce physical and chemical changes in
Roasting ● Roasting ovens
food material, such as texture or flavor
● See Baking Equipment Employed
● Assists in the preservation of food matter by destroying
microorganisms and reducing the amount of water at
the food surface
● Suitable for meats, nuts, vegetables, etc.

● Processes food material under high temperatures

(100+ °C) to inactivate all microorganisms and
Sterilizers/sterilizing retorts
enzymes (including microbial spores)
● Can be heated by steam, hot water, or direct flames ● In-container sterilizers
Sterilization
● Produces food products with long shelf lives (long-term ● Continuous flow sterilizers
preservation method)
Heat exchangers
● May result in a significant impact on quality and
characteristics

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Food Preservation Equipment
Preservation Method Description Equipment Employed
Natural

● Salt (salting)
● Employs natural and non-natural chemical substances ● Smokers (smoking)
to prevent or inhibit spoilage ● Acids (e.g., acetic acid, vinegar, etc.)
Chemical
● Can change the pH and other qualities of food Non-Natural
material
● Sorbic acid
● Sulfur dioxide
● Benzoic acid

Blanchers
Heat Processing
● Heat Processing Equipment section ● Steam blanchers
(Application of Heat)
● Hot water blanchers

● Employs ionizing radiation to destroy microorganisms

● Irradiation equipment, such as isotopes and electron
Irradiation and inactivate enzymes which cause spoilage
accelerators
● Little to no heating of food material

Chilling (-1°C–8°C)

● Chillers
● Reduces the temperature of food material to depress ● Mechanical refrigerators
the biochemical and microbiological processes of ● Cryogenic systems
microorganisms and enzymes which cause spoilage
Refrigeration(Removal of Heat) Freezing (below freezing point)
● Helps maintain quality and characteristics of food
material
● Freezers
● Mechanical refrigerators
● Cryogenic systems

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Common Types of Food Packaging Equipment

Equipment Employed Function Description

Printers Packaging Material Creation ● Enables the identification of food contents and the
(e.g., flexographic, photogravure, planographic, screen, or indication of handling, storage, and usage instructions
inkjet) (e.g., ingredient list, production date, barcodes, etc.)
● Allows for branding and marketing (e.g., brand name,
logo, etc.)

Volumetric Fillers Filling ● Used to fill a set volume of the packaging containers
with liquid, paste, or small pieces of solid food material

Net-weight/Gross-weight Fillers Filling ● Used to fill packaging containers with a specific weight
of liquid, paste, or small pieces of solid food material

Seamers Sealing ● Creates a double seam in filled food and beverage cans

Form-Fill-Seal (FFS) Systems Sealing ● Capable of forming, filling, and sealing flexible film
packaging containers

Checkweighers Quality Control ● Verifies that filled packaging containers are at the
required fill weight and removes underweight products
from the production line

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Basic types of layouts

1. Production or line layout

2. Process or functional layout
3. Cellular or group layout
4. Fixed position layout

Basic departments of food and beverage industry Facilities required in the processing room

1. Delivery 1. Changing room

2. Temporary storage of raw materials 2. Separate hand washing facility
3. Storage of processed materials 3. Toilets (separated by atleast two doors or located in a separate building)
4. Processing 4. Chemical storage room
5. Storage of other raw materials
6. Utilities
7. Effluent treatment
8. Laboratory and R&D
9. Offices
10. Employment facility room
General layout model for food and beverage industries
Primary Manufacturing Area
The product that arrives from the secondary manufacturing area is exposed to the facility environment in the primary manufacturing area, drastically increasing the contamination risk and
thus it should be the most protected area of the manufacturing process.

The product usually enters the primary area through pressurised air locks. Personnel also must enter through air locks and undergo gowning changes.

The air in this section must be conditioned as a standard

Secondary Manufacturing Area

The product is first exposed to the facility environment in the secondary manufacturing area. The raw material enters the secondary manufacturing area from the stores.

secondary manufacturing area is the entity in which the final packing of the product takes place.

Aiir locks need to be placed between the stores and secondary manufacturing area to prevent contamination through leaking air.

The personnel entry to the secondary manufacturing area is from the administration area and that too needs to be through air locks.

Warehouse
The warehouse holds raw material and packing material for the manufacturing process and finished goods.

The warehouse is divided into two sections: Store A and Store B.

Store A keeps the raw material and packing material. All these materials are in the quarantine area until they pass the quality check.

Store B holds finished goods. The finished goods are released from the store once the quality checks are over.

The goods movement from the stores is in one direction. There is no back tracking or criss-crossing of material movement on the layout.

Utility Area
This area hosts all utilities and the engineering department of the organisation.

Utility equipment includes components such as air handlers for the heating, ventilating and air conditioning (HVAC) system, boilers, air compressors, chillers, and water purification plants that
support the manufacturing process.

Administration Area
This area holds the facilities such as the main administration office, changing rooms for employees, canteens, washrooms, toilets, and first aid rooms.

Employees use the changing room in the administration area and wear the factory uniform and sanitise their hands before entering the secondary manufacturing area.
Program

1. Primary manufacturing area

2. Secondary manufacturing area
3. Warehouse
- Cooler
- Freezer
- Shipping & receiving
- Equipment storage
4. Administration area
- Administration office
- Training room
- Quality assurance lab
- Changing rooms
- Canteens
- Washrooms
- Toilets
- First aid rooms
5. Utility area
- Water purification plant
- Boilers
- Trash room
- Mechanical room
- Electrical room
6. Visitor’s room
7. Testing kitchen
8. Conference room
Fish and Shrimp Processing
Shrimp processing industry
Refrigeration is the heart of fish or shrimp processing plant. It all starts with the use of ice from the time of harvesting until it reaches to final consumer kitchen.

every part inside the processing plant maintains a lesser temperature than the ambient temperature in most parts of the year. It means the building is energized,
even more; appropriate to say that it is refrigerated.

Cold Storage Area

Above all the cold storage is the area where it is necessary to provide high priority during design. This is where final money is sitting. The cold storage consists of
three sectors. The storage area, anteroom and the material dispatch area.

Commonly used material storage systems in the industry are,

1. Mezzanine floor (Multi-tier flooring)

2. Drive-in racking
3. Single deep racking
4. Double deep racking
5. Mobile racking
6. Pallet Shuttle system

Single deep racking

Mezzanine floor Drive-in racking Pallet Shuttle system

Shrimp processing factory layout
Source- FAO
For the docking area the best method to load/unload
material is by using a dock leveller which bridges the
gap and height between the building and the vehicle.
The height and position of the dock leveller should be
well suitable for refrigerated trucks and container
docking. Forklifts that are suitable for container loading
can minimize the loading-unloading time very
effectively.

Shrimp processing
machine
Livestock is one of the fastest growing industries in Bangladesh, contributing about 1.90 percent to the country’s GDP and 16.52 percent to the agriculture
sector in FY 2021-22. Due to government support, improved medical care, artificial insemination to increase production, the use of automation and
technology in firms, and increased investment, the number of livestock is constantly increasing and the growth of the sector is accelerating. In FY 2021-22,
the total amount of livestock in Bangladesh exceeded 43 crores. Due to this Bangladesh is now self-sufficient in meat production and can meet the population
demand for 830 grams of meat per capita.

Source: businessinspection.com.bd
Reasons Behind Growth
Skilled Manpower
At present, educated unemployed youth in Bangladesh are interested in raising poultry and cattle rather than looking for employment. Educated farmers are able to use modern
technology in their farms for managing farms properly, providing proper feed, and supplying necessary medicines. Thus, they also benefit from this development, and the
livestock sector is rapidly expanding.

Increasing Protein Consumption

Bangladeshi consumers have become aware of protein-rich foods due to their increased affordability. In the past, people were unable to afford beef or goat meat because of the
price. Thus, poultry meat was consumed more than these protein foods because of their relatively low prices. Currently, due to an increase in per capita income, affordability has
increased. In addition, consumption and demand for meat like beef and mutton are increasing along with poultry. The growing hotels and restaurants in Bangladesh require large
quantities of chicken meat, beef, and mutton daily to meet the needs of customers. Thus, the constant growth of hotels and restaurants and their consumption of large quantities
of poultry and meat have played a crucial role in the growth of the entire livestock industry.

Increasing Investment
The livestock sector in Bangladesh receives increasing amounts of investment every year. According to a BPICC source, investment in poultry in the 80s was only BDT 1,500 crore,
which has now reached BDT 35,000 crore. It is estimated that the amount of this investment will double in the next 10 years. Moreover, the entire livestock industry is looking
toward rapid growth and business opportunity, and the biggest conglomerates in the country are also interested in investing in this sector. In 2018, the Bangladesh government
signed a $500 million financing agreement with the World Bank. This agreement supports the development of the country’s livestock and dairy production, as well as better market
access for 20 million livestock farmers and small and medium entrepreneurs.

Source: businessinspection.com.bd
Workflow diagram (cattle meat processing industry)

Slaughtering
jjjlllkhkjlkl
Total land area= 20 acres
Factory building= 4.48 acres
(22.4%)
WTP= .2 acre (1%)
Utilities yard= .2 acre (1%)
Outdoor transformer= .16 acre
(.8%)
Total built form= 5.04 acres
(25.2%)
Stormwater basin= 114 acres
(5.7%)
Greenery= 6.42 acres (32.1%)
Road= 8 acres (40%)
Open space= 9.14 acres (45.7%)

Source: http://www.pgia.pdn.ac.lk/pgia_mis/uploads/lecturenotes/447/1.%20Food%20Processing%20Facility%20Design.pdf
Comparison of case study with Bangladesh Gazette guidelines

Bangladesh Gazette/
Design criteria Provision in case study Remarks
guidelines

3-7 acres for medium and 10-20 acres

Plot size 20 acres Large scale industry
for large scale industries

Total built form 25.2% of total land area Highest 50% of total land area Acceptable

Drive way, open parking, internal

40% of total land area Highest 30% of total land area Acceptable
roads etc.

Open space 45.7% of total land area At least 20% of total land area Acceptable

Parking 188 car parkings 1 car parking per 800 m^2 Acceptable
 Comparison of case study with BEZA guidelines

Provisions in case study Allowable design provisions

Program
Producti Produ-
Percen- No. of Percen-t No. of
Area on Area ction
tage/ emplo- age/ emplo-y Remarks Sources Remarks Sources
(acres) capa- (acres) capa-
amount yees amount ees
city city
i. Meat
receiving
Plot size 20 - 2.5 - area= 3%
of factory
building
i.Factory = .55 acre
building= ii. Total no.
25.2% of of cows to
Total built 22% of total
5.04 total land 1,25 50% be
form land area i. Case
area received
= 23958 sft study
analysis per day=
ii. Floor ii. 100 I. Case
Drive way,
space per researchga iii. Weight study
open 40% of
person= 100 te.net of 1 adult analysis
parking, 8 total land .75 30%
sft native ii.
internal area - - 240 .7-1.3 ton
So no. of cow= southcente
roads etc.
workers= 240 150-250 kg rs.osu.edu
iii, iv. The
45.7% of So total Daily Star
Open weight=
9.14 total land .5 20%
space 1.5-2.5 ton
area
Meat
produced
per day=
1 car Bangla- 47%-52% of
188 car 12 car body
Parking - - parking per desh
parkings parkings weight
800 m^2 Gazette
= .7-1.3 ton
Shrimp processing
Depending on the size of shrimp and the availability and cost of labour. shrimp may be processed by mainly mechanical or
manual methods.
A suggested factory layout for processing 800 kg/h of small-to-medium size shrimp using a machine peeling operation is shown
in Figure 67. Prior to planning a factory layout, a flow chart should be prepared and the diagram relating to this operation is
shown in Figure 68.
Larger shrimps are more likely to be suitable for processing with a mainly manual operation, and a typical layout together with the
corresponding flow chart are shown.

Whole fish processing

In this case, a more elaborate flow chart -Figure 71- has been prepared showing the different operations and the movement of
produce and materials such as packaging and ice. The term "whole fish" can cover a wide variety of species and products which
may require different prefreezing and post-freezing treatments. therefore, the layout in Figure 72 only represents a typical case
incorporating many of the elements associated with good practice.
Flow chart for processing medium and small shrimp
Proposed layout and flow plan for 800 kg/h medium
and small shrimp processing plant
Flow chart for processing large shrimp
Proposed layout and flow plan for 2 t/day
hand-peeling shrimp processing plant
Flow chart for whole fish freezing
Proposed layout for whole fish freezing
Site
Location
The following list is not comprehensive, but it gives guidance on some of the factors that may have to be taken into account when
selecting a site for a freezing and cold storage complex:
The cost of land
The location of the site with respect to raw material supplies
The continued availability of raw material supplies
The location of the site with respect to markets and other outlets
Are there likely to be local objections to the complex
Will local conditions add to the building costs
Local rates and taxes
Local grants or other aids available
The cost of site preparation
Availability of sufficient water of the right quality
Adequate power supplies
Are there nearby ancillary support services such as ice plants
The cost of disposal of liquid and solid waste
Is there land and other services available for future expansion
Site level
A flat, level site is preferable since this is likely to result in lower site preparation costs.
However, the cold-store floor level may be raised to provide a suitable loading bank of about 1.4-1.5 m high for vehicles. On
sites where there is likely to be problems with ground flooding, it is essential that the cold store in particular is kept above
the maximum level likely. Elevating the cold store above ground level also allows natural air ventilation to be used to prevent
"frost heave".
For some of the reasons given above, other floor levels in the complex may also be elevated above ground level, but on
some sites a two-level system may be contemplated since some of the needs of the processing area are best served by a
ground-level floor.

Communications
The availability of suitable communications is often the major consideration when choosing a site both for the movement of
goods and for other services such as labour.
Ideally, the site should be close to the source of raw materials, which means that it should be near the point of off-loading
from fishing vessels. However, a major portion of raw material supplies may be consigned from more distant ports and it
may therefore be advantageous to site the complex on the periphery of an urban area to ensure easy vehicle access.
If goods have to be loaded on and off a vehicle for delivery to the complex, it is usually of relative unimportance whether the
journey is very short or say s km, since the time spent on loading and unloading accounts for most of the costs.
It is also often more important to have good communications rather than short journeys, since this will govern the size of
loads to be carried and also transport times.
When journeys are long it may also be necessary to contemplate the cost of breakdowns in communications or the cost of
ensuring that there are adequate contingencies to cope with these situations.
Site size
Adequate space for vehicle access and manoeuvring is of prime importance, and an area outside the main
buildings may also be required for the storage of pallet frames. Vehicle size and the type of operation will be
decisive when planning the layout and size of the site, as also will the need for future expansion. Modular store
construction allows cold store expansion to be achieved by adding on to existing stores, and the site
arrangement should allow this to be achieved with similar standard-sized units.
Parking space for other vehicles and equipment should also be adequate since if no allowance is made they
often interfere with the cold storage and factory traffic.
The factory site
The management of
the premises and site
will give us ample
opportunity to build
up our first line of
defence against
contamination. The
site should ideally be
in an area with good
air quality, no
pollution problems
(e.g. from other
industrial plants),
uncontaminated soil,
well-planned and
with an ample supply
of uncontaminated
water. It should be
noted that properly
maintained
landscaping of the
grounds can assist in
the control of
rodents, insects and
birds by reducing
food supplies and
breeding and
harbourage sites.
Figure 1 shows a
layout of a factory
with key barriers
The building The building is the second major barrier which provides adequate protection
for raw materials, processing facilities and manufactured product from contamination or
deterioration. The building should have adequate protection from rain, wind, water from
surface run off, dust, pests and uninvited people. While designing the factory, consideration
also should be given to facilitate installation and maintenance of factory equipment.
General design issues for the factory interior
The main principles of hygienic design of the interior of a factory unit should be to remove any potential internal sources of
contamination and to prevent any external contaminants from accumulating. The first principle can be achieved in a
number of ways, including the following:
● Materials in the proximity of food processing operations should be non-toxic.
● Glass, wood and other materials that could present a serious hazard to consumers, if fragments, contaminate food,
should be avoided.
● Materials must be durable and able to withstand the operational environment, including extremes in temperature,
physical impact vibration, moisture and corrosion from food materials (e.g. those containing organic acids).
● Services such as water or steam should be designed so they do not provide a growth medium for contaminants (e.g.
through condensation) or become contaminated themselves.
● The pipe carrying treated water for the processing should be colour coded and should be easily distinguishable from
those carrying non potable water.
● No inaccessible areas, cavities or seams where dirt can gather.
Salt Processing
Source: GEA Group
Import
export

Parking lot entrance Main entrance source-Laboratory for Shihlien

Biotech Salt Plant
Fast Moving Consumer Goods
(cakes, biscuits, bread etc)
Source: Neufert 4th edition
Source: Neufert 4th edition
Reference: Ayyappan Pillai, S., 1983. Model layout of fish processing plant. Fish Technology
News Letter. Vol.3 No.9-11 Hall, G.M. and Köse, S., 2014. Fish processing installations:
Sustainable operation. Seafood Processing, pp.311-342. Van Donk, D.P. and Gaalman, G.,
2004. Food safety and hygiene: systematic layout planning of food processes. Chemical
Engineering Research and Design, 82(11), pp.1485-1493. Graham, J. (ed.), Planning and
engineering data. 3. Fish freezing. FAO Fish.Circ., (771):126 p.1984
BEVERAGE INDUSTRY
INTRODUCTION

The large population in Bangladesh has been a blessing for the country
from a business perspective as one of the key indicators of business
attractiveness is population. Like many other businesses, foreign
beverage giants have also entered Bangladesh and doing business for
over a decade. Alongside global giants like The Coca-Cola Company
and PepsiCo, local companies like Pran, Akij Food & Beverages Ltd
(AFBL), Partex Beverages and many others are competing
head-to-head with each other.
All the major players offer a variety of beverage products in the
market. Apart from drinkable water, Bangladesh’s beverage
market comprises of three categories of flavored beverages –
dairy based beverage, carbonated beverage, and juices &
nectars.

common approach of vertical integration is practiced by most companies

of the beverage industry operating in Bangladesh. Mostly, dairy based
beverage brands go for a forward vertical integration to ice cream as
both products share the same raw raw material – Milk. Companies like
Pran, Akij, and Milk Vita who operate in the dairy market either has
presence or is planning to expand to the ice cream market as they often
supply their milk in a powdered form to the ice cream manufacturers.
Obtained information at a glance

● Architect: Salma Akter

● Total no. of workers in Unit 1= 6839 (as per 2022 census)
● Male:female= 60:40
● Total land area= 56 acres
● Total land area of Unit 1= 20.46 acres
● Total land area of Unit 2= 17.15 acres
● Building footprint of coke line= 37200 sft
● Building footprint of bakery line= 54000 sft
● Building footprint of biscuit and wafer line= 20400 sft
● Total no. of workers in coke line= 364
● Total no. of workers in bakery line= 996
● Total no. of workers in biscuit and wafer line= 384
● Production capacity of coke line= 22 KLD
● Production capacity of bakery line= 32000 pieces per day
● Production capacity of biscuit and wafer line= 12000 pieces per day
WORKFLOW
Bakery (Cake line)

WORKING AREA PRODUCTION CAPACITY WORKER AREA TOILET

Processing Area 100

Mixture Room 100

Oven 50

Cream Mixture 32000 pc/day 100

Foil Room 50

Tray Line Area 176

Packing and Cooling 420

Biscuit

WORKING AREA PRODUCTION CAPACITY WORKER AREA TOILET

Fermenting Room 50

Mixture Room 30

Indian Oven 10

Cream Mixture 12000 pc/day 40

Foil Room 25

Tray Line Area 70

Packing and Cooling 164

Coca-cola line ground floor plan
 CAKE LINE

FINISH

START

PACKAGING

FIRE STAIR

TRAY AREA LINE

PROGRAM AREA

PROCESSING AREA 5518 sqft

OVEN 1416 sqft

FOIL ROOM 616 sqft

TRAY LINE AREA 1652 sqft

COOLING & PACKAGING 1236 sqft

OFFICE 904 sqft

CONFERENCE ROOM 241 sqft

CUSTOM ROOM 222 sqft

QC 66 sqft

DINING 508 sqft

CHANGING ROOM AND TOILET 376 sqft

CHEMICAL ROOM 418 sqft

MIXTURE ROOM 1262 sqft

STORE ROOM 564 sqft

MAINTENANCE ROOM 417 sqft

TRAY WASHING 420 sqft

PROGRAM AREA NO OF WORKERS

FILLER 3296

RO PLANT 3361

RAW SYRUP 2153

READY SYRUP 1514

QA LAB 1195

COKE OFFICE 847

DRY BASEROOM 578

HP COMPRESSOR 1438

BLOWING HALL 2160

PACKAGEING AND COOLING 8513

UNLOADING 3810

TOILET 1150

TEMPORARY WAREHOUSE 1784

GENERATOR 471

SUGAR STORE 427

NH3 ROOM 1221

COKE FACTORY
BISCUIT FACTORY
 UTILITY AREA (ACRE)

ETP 01(175 KL/D) 0.3

ETP 02 (1500 KL/D) 0.4

WTP 0.27

SUBSTATION 1.1

RECYCLE PLANT 0.46

Description Size in mts

Raw effluent collection sump 3 dia

Oil and grease trap 6.6x2.6

Equalisation cum neutralisation tank 5.2x5.2

Aeration tank 12dia

Clarifier 4 dia

Mcc &lab room 6x4

Acid dosing tank 3.4x 3.4

Sludge drying bes 8x5 (3 nos)

Fish pond 1.5 dia

Biscuit factory

Bakery (Biscuit)
Cream room
Foil room
ATC room Fermenting
Wafer packing & holding
Wafer oven room
Mix room
Production area Mixing
FG room
Packing room
Cooling room
Indian oven
Indian Oven
Fermenting room
Syrup room
WFP inspection
QC room Cream mixture
Conference room
Administrative area Office room
Guest room
Toilet Foil Room
Washroom
AHU chiller room
Tools room Tray Line Area
DB room
Utilities and Services
Maintenance room
Store room
Cooling

Washroom
Toilet
Employee Facilities Dining Packing
Changing room
Cake factory
Cargo lift x 4 - 11’6” x 11’
Passenger lift x1 - 11’6”x9’3”

Stocking trays area

Mixture room
Bakery (Cake)
Chemical room
Production area
Oven Processing
Cooling and packaging area
Cream mixture room

Mixing

Reception area
Executive office
Office Oven
Administrative area Conference room
QC room
Coding room
Cream mixture

AHU chiller room

Tools room
DB room Foil Room
Utilities and Services Maintenance room
Control room
Tray washing room
Ips room Tray Line Area
Washroom
Toilet
Employee Facilities
Dining Cooling
Changing room

Packing
Biscuit factory

Cream room
Foil room
ATC room
Wafer packing & holding
Wafer oven room
Mix room
Production area
FG room
Packing room
Cooling room
Indian oven
Fermenting room
Syrup room
WFP inspection
QC room
Conference room
Administrative area Office room
Guest room
Toilet
Washroom
AHU chiller room
Tools room
DB room
Utilities and Services
Maintenance room
Store room

Washroom
Toilet
Employee Facilities Dining
Changing room
Coca cola factory

Pre form room

HP compressor room Coca Cola
Blowing room
Production area Filler room
Production room
Raw syrup room
Ready syrup room
Raw Syrup Production

Eng office
Acc office
Washroom
Lab office
Administrative area QA lab Ready Syrup Production
Sensory lab
M lab
Production office

AHU chiller room Carbonation

D base
Tools room
DB room
Maintenance room
Unloading area
R.O plant
Utilities and Services Filling
Boiler
Generator
Warehouse
Loading area
Store room
Waste management area
ETP Packing and distribution
Washroom
Toilet
Employee Facilities
Dining
Changing room