Introduction: In the heart of Uttar Pradesh, an architectural and engineering marvel rises 63 m into the skyline — a pre-engineered process tower built for Hindustan Unilever Ltd (HUL) by Interarch Building Solutions. This case study delves into the complexity, execution finesse, and sustainability-led design of a project that sets new benchmarks for PEB systems in India.
|
Project Fast Facts Client: Hindustan Unilever Ltd Location: Sumerpur, Uttar Pradesh Total Area: 35,000 m² Building Height: 63 m (11 floors) Tonnage: 5,000 MT Consultants: L&T Technology Services Project Value: ₹56 crore |
At HUL’s Greenfield site in Sumerpur, Interarch was entrusted with delivering a 63 m high spray-dried detergent process tower as part of a 35,000 m² manufacturing facility. The project demanded not only vertical scale but meticulous attention to load dynamics, equipment integration, and inter-building junctions, all managed through Interarch’s proven turnkey steel construction approach.
With a total tonnage of over 5,000 MT and a project value of ₹56 crore, this was no ordinary assignment. The facility includes seven distinct structures: process tower, packing hall, raw material store, HAG biomass unit, utility structure, SFG section, and pipe racks.
DESIGN THINKING WITH PRECISION
- Structural analysis was conducted using STAAD Pro and in-house parametric tools.
- The Process Building are designed for high-performance live loads (up to 10 kN/m²) on mezzanine floors.
- All structures were engineered as per IS 800:2007 standards.
- The design allowed for heavy MEP collateral loads, solar panel integration, and dynamic junctions, especially critical for a structure this tall.
CONSTRUCTION COMPLEXITY
The 11-storey process tower houses complex mezzanine systems with heavy equipment loads.
Key challenges included:
- Interfacing with multiple adjacent structures
- Managing joint integrity to ensure leakproof roofing (achieved using Interarch’s TRACDEK® SS-2000 standing seam roofing system)
- Meeting high functional and seismic performance standards
Despite adverse conditions, Interarch delivered with clockwork precision, owing to a robust site management system and strict adherence to safety protocols.
“This is not just a PEB building, it’s a mission-critical vertical factory where every level carries a load of performance, precision, and innovation.”
SUSTAINABILITY AT SCALE
Designed to have a zero-carbon footprint, the facility aligns with HUL’s global sustainability goals. Interarch’s construction methodology minimised material waste and optimised energy efficiency at every stage, from design to fabrication and erection.
LEGACY OF IMPACT
Having successfully completed similar facilities across 11 locations for HUL, Interarch has demonstrated its ability to deliver high-stakes industrial projects at scale. Their work at Sumerpur now stands as a national benchmark for tall PEB buildings.
Voice from the Field:
“Every aspect of the project was well coordinated on this highly challenging project despite encountering the pandemic scenario. The workmanship was of very high calibre, and the team demonstrated impressive overall quality of installation and attitude towards work. Interarch’s excellent support in design, fabrication, and erection of steel building with all the safety standards has been a major factor in achieving success in the project with great efficacy.”
– Sqn Ldr Anusha Raghav, Former Project Delivery Manager, HUL Sumerpur
“Proud to be part of Unilever’s iconic process plant project at Sumerpur, executed in steel by Interarch. This 63 m tall structure is a showcase of advanced PEB engineering, delivered on time with precision and care. Designed for sustainability, the plant smartly uses gravity-based material flow, reducing energy use and improving process efficiency. Thank you, Unilever, for your continued trust in Interarch. Together, we’ve built more than a plant — we’ve built a future-ready, sustainable solution.”
– Rinku Kedia, VP – Sales & Marketing, Interarch Building Solutions Limited
Engineering Beyond Limits
- Over 40 years of turnkey PEB expertise
- Full-spectrum services: Engineering, manufacturing, erection
- Multi-junction, leakproof PEB systems
- Internal standards of safety and quality control are followed at the site
- Custom detailing for solar, MEP, cranes, and pipe systems
Why It Matters?
The HUL Sumerpur process tower is not just the tallest pre-engineered building of its kind in India, it is a defining moment for the country’s industrial steel construction sector.
By achieving 63 m verticality within a PEB framework, Interarch has redefined the limits of modular steel engineering, proving that speed, precision, and sustainability can coexist at scale. The project demonstrates how tall, mission-critical industrial facilities can be delivered with:
- Optimised structural efficiency through advanced analysis and in-house design tools.
- Sustainability at scale, including a zero-carbon footprint target and gravity-assisted process flows that reduce operational energy.
- Integrated functionality, where heavy MEP systems, solar installations, and complex inter-building junctions work in perfect synchrony.
This accomplishment sets a national benchmark for vertical industrial PEB projects, offering a replicable model for high-performance, future-ready manufacturing infrastructure in India.
