PEP Foods’ new manufacturing facility near Pilvai village, Mehsana, Gujarat, is a cutting-edge plant specifically designed for the production of its flagship frozen food products. Advances in technology have made it possible to preserve food longer, particularly through freezing.
This industrial complex features a sophisticated architectural layout, including multiple mezzanine levels with varying heights, integrating both high and low bays. The high bay area achieves a maximum clear height of 15 m, while the low bay sections maintain a minimum height of 9.7 m. The structural design incorporates a walkable false ceiling system, suspended directly from the roof structure, allowing for both operational accessibility and maintenance ease.
The building spans a total width of 51 m, with a 35 m wide grid structure designated for housing advanced, high-performance machinery, where the majority of the plant’s operations will be concentrated. The internal staircase configuration is engineered to provide seamless vertical circulation across multiple mezzanine floors. The external envelope of the building is aesthetically completed with a combination of ACP (Aluminium Composite Panel) cladding and a glass façade, contributing to both the visual appeal and thermal efficiency of the structure. The design phase was executed in collaboration with Tata Structura, ensuring that all structural elements met stringent performance criteria.
Engineering Excellence
The structural design of the facility adheres to the IS 800:2007 code of practice for general construction in steel, considering the plant’s location within Seismic Zone III, which demands enhanced structural resilience to seismic forces. The design also accommodates additional live loads, particularly utility racks that are integrated into the building columns. These racks are fabricated using high-strength Tata Structura tubes, with cross-sections of 240 x 120 x 4 mm and 200 x 100 x 4 mm, selected for their superior load-bearing capacity and structural efficiency.
Given the critical hygiene standards required in the food processing industry, the grid structure area, where a walkable false ceiling is installed, was engineered using Tata Structura tubes. These sections provide the necessary structural rigidity, adaptability, and rapid erection capability, which are crucial for minimising on-site construction time while maintaining strict quality controls. The specific sections utilised include 300 x 150 x 6 mm, 122 x 61 x 4.5 mm, and 60 x 60 x 2.6 mm, each selected based on their ability to meet both structural and functional requirements.
Curved Facades
The construction of this 5,600 sq m facility presented several technical challenges, primarily due to its weight-to-area ratio, which is approximately 120 kg per sq m, with a total building weight of around 700 MT. Of this, around 80 MT consisted of Tata Structura tubes. The availability of these prefabricated structural elements on-site enabled a streamlined construction sequence, reducing overall project timelines and ensuring adherence to the planned schedule.
A major challenge in execution was the precise alignment of the facade supporting structure, particularly at the intersections with the curved eave and valley gutter system. This system was engineered for efficient water management, channelling flow from the building’s interior to the exterior. The facade also featured several curved elements that necessitated custom-fabricated sections, including 4 mm thick bent plates, to meet the required aesthetic and structural standards.
Initially, the walkable false ceiling was considered for design using built-up sections; however, Tata Structura tubes proved to be a more practical and efficient choice.
Rapid Construction
The external façade of the building, composed of ACP panels and glass, is supported by a framework of Tata Structura tubes. The front elevation of the building features a complex curvature, which requires precise engineering to achieve the desired architectural effect. For this, larger sections, such as 300 x 300 x 8 mm and 150 x 150 x 5 mm Tata Structura tubes, were employed. The consistent quality, ductility, corrosion resistance, concentric strength, low carbon content, and rust-free surface finish of these tubes were essential in addressing the design challenges.
The external staircase, designed with a single stringer, was initially planned using built-up sections. However, after further engineering analysis, Tata Structura tubes (Section Size 200 x 150 x 8 mm) were deemed the most suitable option due to their perfect curved edge and high strength. The unique structural configuration of the staircase presented an alignment challenge, but through meticulous planning and execution, the installation was completed with precision.
Additionally, the building’s partition walls, constructed using PIR (Polyisocyanurate) panels, were supported by a framework that fell within the PEB scope of work. This required careful coordination to ensure that all structural supports were accurately positioned to maintain the integrity of the partition walls.
Despite these challenges, the project was successfully completed within a five-month timeframe. The use of Tata Structura tubes, which accounted for approximately 12 per cent of the total building weight, was instrumental in achieving rapid construction progress while meeting all design and aesthetic requirements. This project exemplifies the successful integration of advanced structural engineering principles with innovative construction techniques, resulting in a facility that not only meets but exceeds the stringent demands of the modern food processing industry.
Fact File
Project: PEP Foods Manufacturing Facility, Gujarat
Client: PEP Foods
Consultant: VMS Engineering & Design Consultants P Ltd – Ahmedabad
PEB: Shree Prefab Steels Pvt Ltd
Tata Structura Quantity: 80 MT
Tata Structura Serviced By: Devam Enterprise
Quote
“Engineering excellence meets innovation at PEP Foods Pvt Ltd’s state-of-the-art facility in Gujarat. This project stands as a testament to the power of advanced structural design, where every element—from the intricate façades to the robust internal frameworks—was meticulously crafted with Tata Structura tubes. Overcoming complex architectural challenges, the integration of strength, precision, and aesthetic finesse has created a facility that not only supports high-performance manufacturing but also sets a new standard in the food processing industry. The successful collaboration among all stakeholders reflects a shared commitment to quality and innovation, delivering a structure that exceeds expectations in both form and function.”
– Kinjal Dave, Project Director, VMS Engineering & Design Consultants P Ltd – Ahmedabad; & Devam Shah, Executive Director, Shree Prefab Steels Pvt Ltd & Devam Enterprise
