Industrial Innovations

Project: Dr.Oetkar Food Processing Factory, Kaharani Industrial area, Rajasthan

Architects: ENAR Consultants, New Delhi

The language for notable contemporary industrial projects in India is defined by the structural innovations. Continuing this philosophy, this industrial project for a processed food major at Kaharani Industrial area in Rajasthan utilises pre-tensioned precast technology to create a large span structure with impeccable finishes to comply with European standards. Spread over approximately 210,000sq ft on a 15-acre site, the building has been planned on a 10m x 15m grid.

The structural elements such as the columns, beams and slabs were manufactured at the production facility at Manesar, Haryana, and then transported to site for erection. The quality of manufacturing ensures that the precision of the elements is extremely high, resulting in a superb interior finish. This technology also ensures that the time taken for erection is much less than conventional systems and uses substantially less manpower. This technology has high relevance for buildings with replicated modules such as schools and colleges, and we are currently designing several proposals for educational buildings based on this technology.

The project is a zero-discharge unit and has been designed to be extremely frugal in resource consumption. All the liquid wastes are recycled or used in irrigation. The project uses a vacuum distillation unit to extract substantial amounts of RO quality water from RO wastes and WTP backwash water. The building is completely insulated and even though the wall work is in AAC blocks, further efficiency has been achieved by using 100mm thick EPS to almost eliminate heat gain. The production areas are lit up with linear skylights eliminating the requirement for artificial illumination during most production hours. The roofs have been laid on a slope to ensure that there are no rainwater pipes in the production facility, rather edge gutters drained by state-of-the-art symphonic drainage systems have been implemented for rainwater drainage.

The facades are made in PVDF aluminium cladded Kalzip panels to create a maintenance free facade. The front elevation however is a fusion of modernity and tradition, created in locally available shot blasted sandstone and aluminium composite panels to reflect the architectural language of the region of Rajasthan and the European stylisation respectively. The project was visualised to conform to stringent European standards upholding the world-wide design language of the Oetker group, while using locally available materials and adapting construction methodology to ensure a high degree of accuracy in the construction elements. For this reason, the industrial component of the project was executed in precast pre-tension RCC construction. Energy saving was an important aspect of the design process. The annual variation of temperature in the project site of up to 42 degree Celsius resulted in implementation of a high degree of insulation in wall and roofs of the project. This has resulted in substantial reduction of heat gain which in turn has resulted in saving energy cost. The work areas are all extensively daylit, eliminating the need for artificial lighting during the daytime.




All fenestration is equipped with high performance DGU units to cut out heat gain. On the technological side, the air conditioning system uses air instead of water for cooling as the site is in a critically over-exploited zone as per classification of CGWA and the use of minimum water is an important part of the design brief. Heat recovery cycles have been implemented at every fresh air intake to optimise energy consumption. Even utilities like the boilers have air preheaters implemented to withdraw maximum heat from the flue gases to heat up incoming air and save energy substantially. Superheated condensate is also utilised in the hot water generator to extract the heat energy from what can be a waste product. The electrical system is made efficient by implementing variable frequency drives on every power consuming equipment such as pumps, motors, and compressors to optimise energy saving. All illumination in the project is by LED lighting fixtures.

This coupled with the extensive daylighting in the building results in saving the energy bill. Solar energy has also been harnessed to ensure that. Dr Oetker took to creating rainwater harvesting structures in the villages in the surrounding areas as a part of its corporate social responsibility to give back to the immediate environment twice of what was extracted. Thus, groundwater levels in the surrounding villages has increased, thereby improving the quality of life of the residents in this arid region of the country. Rainwater falling within the site was also harvested by using innovative modular cellular structures made from wastes and recycled plastics. This ensured that concrete drains, soak pits etc. were eliminated and a simple, quick, and economical solution was implemented. Also, frugal water consuming units such as high efficiency fixtures were implemented, 100% water is being recycled and treated water is being used for flushing and gardening. Creating a zero-discharge water balance ensured that a fraction of the total water that could have been required was consumed. One of the biggest challenges to achieve this was recycling the RO and the WTP backwash wastes.

Since the processed food industry extensively uses high quality water treated through a reverse osmosis process, it also generates a large amount of process waste. This high salt laden water is unfit to be treated by any conventional means. To achieve this, a vacuum distillation device has been installed to recover about 16,000 litres of water daily which would otherwise have gone to waste.

Fact File

Client: Dr Oetker India Pvt Ltd

Design team: Amit Khullar, Dipankar Mazumdar, Pankaj Khullar, Anubha Khullar, Hemchandar Khohal, Harshita Sharma, Sukhraj Kaur, Aastha Sharma, Vikas Negi; General Designer: Ion Ionescu, Germany

PMC team: Rashid Qadir, Bineet Rohilla, Ehtesham Husain, Motiur Rehman

Consultants: Structural Consultants: RSM Engineering Consultants, New Delhi; MEP Consultants: V S Kukreja and Associates, New Delhi; Landscape Consultants: Studio ATK, New Delhi

Contractors: Civil Contractor: Survi Projects Pvt Ltd

MEP Contractor: Blue star India Pvt Ltd; Interior Contractor: Star Infra Pvt Ltd; Landscape Contractor: Vividh Landscapes

Built-up area: 2.10 lakh sq ft (approx)

Cost: Rs 215 Cr

Year of completion: 2016