Nescafé 3 In 1  Expansion Project

Project Overview

The Nescafé 3 expansion project was developed as a new production area within the Nestlé Iran site, with the objective of creating additional process capacity for coffee-based powder products while meeting the factory’s technical, hygienic and operational requirements. The scope was not limited to equipment installation. It covered the chain of works required to turn an allocated area into a functioning process line, including area preparation, selected civil modifications, structural steel, equipment handling, mechanical installation, hygienic piping, utility distribution, electrical works, instrumentation, automation coordination and commissioning support.

From an engineering perspective, the project required close coordination between process design, equipment layout, structural support, access planning and service routing. Powder handling systems, bulk ingredient receiving points, intermediate transfer sections, process mixers, sieving arrangements and downstream interfaces all had to be positioned with enough accuracy to support reliable operation, cleanability, product flow and long-term production stability. This is especially important in food production, where the quality of installation has a direct effect on the way the line performs from its first operating cycles.

The installation package also involved integration of supplied equipment from specialized vendors, including Gericke systems and associated ancillary items. Such equipment cannot be treated as ordinary static machinery. Accurate setting out, proper support conditions, coordinated connection points, controlled lifting procedures, suitable vibration isolation where required, and correct interface installation all affect final performance. For this reason, the project was executed as a coordinated engineering package rather than as isolated trade activities.

In parallel with the installation works, the project team had to maintain a disciplined approach to materials, documentation, labeling, inspection and handover. In food factories, technical completion is not only about mechanical completion. It also depends on traceability of components, quality of fabrication, documentation of changes, proper identification of services, and readiness for cleaning, test runs and operation. The Nescafé 3 project was therefore managed with attention to both construction quality and operational readiness.

Engineering Scope and Delivery Approach

The project started from a defined area intended for the new line. This made the delivery model fundamentally different from a simple modification inside a running process island. The engineering task was to establish the new line from the ground up, beginning with area preparation, floor and structural interventions, utility planning, equipment positioning and connection logic. At this stage, layout control was one of the key success factors. The route of powder transfer lines, the elevation of platforms, the loading conditions of support structures, and the serviceability of valves, instruments and access points all had to be coordinated before installation progressed too far.

The works were executed through staged release of fronts. Civil readiness, steel erection and equipment installation had to progress in sequence, but with enough overlap to keep the schedule moving. This required practical planning between fabrication, site handling and field installation teams. In projects of this kind, delays are often caused not by major technical issues but by unresolved interfaces such as missing supports, conflicting service routes, inaccessible operation points or late changes to nozzle positions. The delivery approach therefore emphasized field verification, interface checks and progressive confirmation of installation levels and connection points.

Another important aspect of execution was protection of equipment and installed finishes. Powder handling components, load cells, flexible connections, seals, filters and instrument assemblies are sensitive items. They must be stored, lifted and installed under controlled conditions to avoid damage, contamination or misalignment. The project team applied this level of care throughout mechanical and electrical installation, especially in areas that would later require hygienic acceptance and reliable process performance.

Civil Works and Structural Modifications

The new process line required substantial enabling works before equipment installation could begin. These works included floor openings, local demolition where technically required, preparation of foundations and execution of civil modifications needed for vertical material transfer, structural seating and service routing. In food industry projects, civil works are rarely limited to simple concrete activities. Openings must match process routes, support arrangements must align with equipment loading data, and all details that affect cleaning or finishing quality must be considered early.

Structural steel formed a major part of the package. New columns, beams, support frames and equipment platforms were installed to carry process equipment, piping, access routes and operating loads. Structural installation had to be coordinated not only with the equipment supplier’s layout but also with safe operator movement and future inspection requirements. Platform heights, access stairs, clearance around operating stations and service approach to motors, valves, load cells and inspection points were all reviewed as part of the installation logic.

Anchor installation, base preparation, alignment checks and steel erection tolerances were handled as controlled activities rather than simple site erection tasks. This approach is necessary where downstream equipment alignment depends on the accuracy of the primary support structure. Even small deviations can affect powder flow, pipe slope, support loading or fit-up at later stages. Once the steel package was in place, the area could support the mechanical installation sequence with better reliability and fewer site corrections.

Finishing works such as floor treatment, local repair, edge protection and suitable hygienic detailing also contributed to the final condition of the area. In projects destined for food production, these items are not cosmetic. A poor joint, exposed rough edge, inaccessible recess or weak finish around equipment bases can later become an operating problem or a hygiene concern. The project therefore addressed the area as a future production space, not merely as a completed construction zone.

Hygienic Piping, Utility Connections and Fabrication Quality

A food production line depends heavily on the standard of its piping installation. In the Nescafé 3 project, the hygienic piping package was developed to support process requirements, cleaning expectations and practical accessibility. Fabrication and installation quality were important at every stage, from spool preparation and welding discipline to slope control, support spacing and final fit-up. Dead spots, unnecessary pockets, poor access to dismantling points or inconsistent weld quality can all create future operational and cleaning issues.

Hygienic welding practices, controlled fabrication procedures and clean installation conditions are central to a reliable food-grade system. Where stainless steel lines are used, fit-up discipline, purge quality for TIG welding where required, surface treatment and protection of completed sections all influence long-term service performance. Equally important is the interface between hygienic piping and non-product utilities. Compressed air, steam, condensate, dust extraction and other services must be routed in a way that supports the process without compromising cleanability, safety or access.

The utility package also required practical engineering judgment. Service points had to be brought to equipment in line with vendor requirements and site standards. Isolation, drainage, support, routing and identification all had to be considered as part of the final installation. It is common for utility systems to create congestion around process equipment if they are introduced too late or routed without enough coordination. For this reason, utility installation was treated as an integrated part of the overall line design rather than as a separate afterthought.

In addition to process and utility piping, local ducting, connection pieces and fabricated supports had to meet a suitable standard for operation in a food factory environment. This included practical requirements such as good access for inspection, avoidance of unstable improvised supports, proper edge finishing and a generally clean installation appearance. Good engineering in this context is not about decorative presentation; it is about building a system that can be operated, inspected and serviced with confidence from the beginning of its production life.

Commissioning Preparation and Operational Readiness

A new production line is not complete when the last bolt is tightened. For the Nescafé 3 line, readiness for commissioning depended on the quality of pre-startup checks and the condition of the installed systems. Mechanical completion had to be matched by cleaning readiness, utility availability, electrical verification, instrument checks, rotation confirmation where applicable, access closure, and removal of temporary works. This stage links construction quality directly to startup performance.

During pre-commissioning, even small installation issues can become significant if they affect product flow, weighing stability, valve operation, seal condition, access to inspection points or cleaning practicality. A disciplined close-out process reduces startup delays and helps the operator receive the line in a more stable condition. Where the installation team remains engaged during this phase, adjustments can be made more efficiently because the site knowledge is still present.

The transition from construction to operation also depends on practical handover quality. Operators and technical teams need equipment that is clearly identified, accessible and logically arranged. They also need records that reflect the actual installed condition. This is particularly important for future expansion, spare part tracking and troubleshooting.

The value of the Nescafé 3 project lies not only in the installed assets but in the quality of execution behind them. A well-delivered new line is one that supports production targets, can be operated with confidence, and remains aligned with the standards expected in a modern food manufacturing environment. That is the real measure of engineering delivery in a project of this type.