Building a packaging plant

MAISSION TO DESIGN THE BRSA MANUFACTURING AND STAMPING PLANT  

Project features

The project was carried out on a 15-hectare plot, which includes all plant functions.

The plant is sized to accommodate 10 filling lines for soft drinks (sodas, still drinks, syrup, milk). With production between 10 000 and 18 000 units per hour depending on the lines.

At the end of the packaging lines, production is palletized. The flow of pallets is transported by automatic conveyors (AGVs) to the automated high-bay warehouse. :

Logistics – preparation – packaging :

• Approximately 33 000 m² of allocated space
• Winery storage capacity 7,000 m³
• Milk pre-treatment capacity 40,000 L/h
• Utility and process fluids are transported in a rack suspended from the roof structure, which represents a total of 8.9 km of stainless steel pipes.

Finished goods inventory – shipping  :

• Approximately 12 000 m² of floor space
• The storage of finished products is carried out in a high bay warehouse of 6 000 m² surface area and 38 m height
.
• The warehouse integrates 8 automated stacker cranes enabling the management of 40 000 pallet locations
• Maximum pallet flow in is 165 pallets/h, out is 280 pallets/h

Technical premises :

• Approximately 3,000 m² of technical premises including production in a power station (HTA – Cold – Steam – Compressed air), distribution premises and maintenance area
• Cooling power of 2500 KW by BP compressors and 3 MP compressors running on ammonia
• Hot water production capacity at 85°C of 1250 KW
• 1 boiler house consisting of 2 steam boilers of 12t/h each for 19.8 MW of power
.
• 1 Local compressed air BP  7 bars
• 1 compressed air room HP 40 bars
• 1 HTA loop covering the entire site with 3 main premises, each equipped with 2 transformers 1600 or 1250 kVA and 2 other secondary premises (STEP and Exterior) Power electricity : 8.5 MVA

Administrative premises :

• Approximately 7,000 m² of administrative space including laboratories, social rooms, guardhouse and drivers’ house.

The networks :

• 8.9 km of wet networks (stormwater, wastewater, drinking water and fire),
• 17 km of dry networks and 170 km of electrical cable used
• Containment of fire-fighting water  : 3,800 m³ of underground storage to receive fire-fighting water

Together, including machine circulation, this represents a floor area of 56,600 m² approximately. To which must be added :

• Industrial water pre-treatment plant (treatment of approximately 300 000 m³ of annual effluent)
• Parking lots, maneuvering areas, docks, outdoor pallet storage (50 000 m²)

At its peak, this site mobilized around 200 workers.

SOME OTHER FIGURES :

• 160,000 m3 of earth movements (excavated material reused as backfill after treatment)
• 28,022 sprinkler heads distributed between the plant and the high-rise warehouse for a total weight of 702 tons of sprinkler piping
• 431,761 m³ of covered warehouse volume and 1,100,000 bolts used for crate assembly

EcoResponsible packaging plant solutions

This new site has been designed to meet ambitious environmental objectives in terms of water and energy savings. Other solutions employed in the design are also worth highlighting :

• The layout of the project has enabled the reuse of excavated material to create the platforms, which has enabled us to minimize the transport of materials
• The retaining wall made of gabions with materials partly sourced from the site, acts as a sound barrier in its south-western section
• Heat recovery at the compressors to provide heating for offices and storage facilities, for a total energy of 6.4 GWH/year.
• The creation of roadway structures by incorporating plant fibers in the binder on 30 000 m² of HGV roadways. This process (SATIS) is applied to 30 000 m² of heavy roadways, limiting the appearance of surface cracking and reducing the quantity of bitumen required. Produced in the Pays de Loire region, the hemp comes from the Vendée agricultural cooperative CAVAC.

Project completion

The site was handed over in February 2024. When completed, the new plant will have tripled its production and packaging capacity while improving its environmental and social performance.