FMCG Industry
Comprehensive Solutions for the FMCG Industry by Collabtec
FMCG Industry in India: Market Overview & Opportunities
The FMCG industry (Fast-Moving Consumer Goods) stands as one of the largest sectors of the Indian economy, accounting for a significant share of GDP. With a rapidly growing population, increasing urbanization, and rising disposable incomes, the demand for packaged food, beverages, personal care, and household products has witnessed exponential growth. As per industry reports, the Indian FMCG market is expected to reach USD 220 billion by 2025.
However, with growth comes stringent regulations, high competition, and increasing consumer awareness regarding safety, hygiene, and sustainability. Hence, for companies to thrive in this highly dynamic sector, it is imperative to focus on certified infrastructure, hygienic manufacturing practices, optimized design, and regulatory compliance.
That’s where Collabtec Engineering comes in as a reliable partner for food and beverage companies aiming for global standards.
Food Processing Plant Design
Modern food processing plant design is a critical factor in ensuring production efficiency, product quality, and hygiene compliance. Collabtec brings domain expertise to plan and execute end-to-end plant designs tailored for the FMCG industry. We design processing lines for:
- Dairy
- Beverages (non-alcoholic and alcoholic)
- Packaged snacks
- Confectionery
- Ready-to-eat meals
Our team ensures proper zoning, material flow, separation of raw and processed areas, and easy sanitization. This mitigates cross-contamination risks and aligns with FSSAI, WHO, and international safety standards.
HACCP Compliance Facilities
Hazard Analysis and Critical Control Points (HACCP) is a globally recognized food safety protocol. Collabtec builds HACCP-compliant facilities that meet the highest standards of preventive control. Our engineering design includes:
- CCP (Critical Control Points) integration within process lines
- Stainless steel surfaces and corrosion-resistant material selection
- Sloped flooring for drainage
- Pest prevention infrastructure
Our expert team ensures that clients are not only audit-ready but also continuously aligned with food safety goals.
Food Grade Cleanroom Construction
Though cleanrooms are often associated with pharma and electronics, cleanroom technology is increasingly being adopted in the FMCG sector, especially for bakery, dairy, nutraceuticals, and infant food production. Collabtec offers modular cleanroom design and construction using food-safe materials.
Benefits include:
- Controlled environments for allergen-sensitive products
- Reduced microbial contamination
- Optimized temperature and humidity controls
We follow ISO classifications and client-specific criteria to build cleanrooms that maintain hygienic integrity and improve shelf life.
FSSAI and ISO Certification Ready Infrastructure
Collabtec specializes in developing facilities that meet the certification requirements for FSSAI, ISO 22000, and GMP. We integrate design and engineering principles to prepare the facility for hassle-free audits and certifications.
Key features:
- Sanitary piping and utilities
- Ventilation systems with HEPA filters
- Separate utility corridors for maintenance access
- Documented SOP support with our advisory team
Our infrastructure ensures a seamless pathway to obtain national and international certifications.
Turnkey Project Execution for FMCG Units
As an end-to-end solution provider, Collabtec undertakes turnkey project execution for greenfield and brownfield FMCG setups. From feasibility study to commissioning, we manage:
- Site Master Planning
- Front-End Engineering Design (FEED)
- Detailed Engineering & Procurement
- Civil and MEP Execution
- Utility Design and Validation
Clients benefit from a single point of accountability and efficient project timelines. Our projects are always designed with long-term scalability and sustainability in mind.
GMP Facility Design and Validation
GMP (Good Manufacturing Practices) is no longer just a pharmaceutical requirement. It is now becoming increasingly relevant in FMCG manufacturing, particularly in health drinks, dietary supplements, and functional foods.
Collabtec provides:
- GMP-compliant architecture
- Hygienic HVAC systems
- Surface finish specifications
- Validated equipment layouts
We assist in generating documentation and validation protocols, such as DQ/IQ/OQ/PQ, enabling a full compliance lifecycle.
Cold Storage and Temperature-Controlled Warehouse Design
Cold chain integrity is vital for perishables like dairy, frozen food, and beverages. Collabtec designs energy-efficient cold storage facilities and temperature-controlled warehouses with:
- PUF insulated panels
- Airlocks and dock levelers
- Refrigeration units with redundancy
- Real-time temperature monitoring systems
Our storage designs adhere to global cold chain norms and ensure product integrity throughout the supply chain.
Sustainable Factory Design for FMCG
Sustainability is a core value in today’s FMCG market. Consumers and stakeholders alike are demanding green practices. Collabtec delivers sustainable factory solutions that reduce environmental impact and operational cost:
- Rainwater harvesting and wastewater recycling systems
- Solar-ready roofing
- Natural lighting and energy-efficient HVAC
- LEED and IGBC compliant designs
We help clients meet ESG goals while gaining cost advantages through operational efficiency.
Utility and Process Engineering
Utility design is the backbone of any FMCG production unit. Collabtec provides integrated engineering for:
- Steam and compressed air systems
- Water purification and CIP systems
- Electrical and automation panels
- Fire safety and BMS
Each utility is meticulously engineered for low energy use, high uptime, and long-term reliability.
Factory Automation and Smart Manufacturing
The shift towards Industry 4.0 and automation has transformed the FMCG industry. Collabtec incorporates automation and digital systems into plant design, offering solutions such as:
- SCADA integration
- PLC-based process control
- Real-time quality monitoring
- Smart packaging lines
We future-proof your facility by making it smart, scalable, and audit-traceable.
Additional Services by Collabtec for the FMCG Industry
Regulatory Documentation Support
Collabtec doesn’t just stop at engineering. We provide documentation packages that include:
- Facility Master Plans
- SOP drafts
- Risk Analysis and HACCP charts
- Qualification documents (DQ/IQ/OQ/PQ)
This ensures readiness for audits by FSSAI, FDA, and other global bodies.
Packaging & Bottling Line Setup
From layout to commissioning, we design high-speed, hygienic, and efficient packaging lines for:
- Beverages
- Sauces and condiments
- Dairy products
- Confectionery
We ensure ergonomic design, operator safety, and hygienic bottling standards.
Fire Safety and EHS Compliance
A critical part of any food unit is its EHS (Environment, Health & Safety) framework. We design:
- Fire exit and sprinkler systems
- MSDS-compliant chemical storage
- Noise reduction engineering
- Employee hygiene areas
Our safety-first approach ensures that your plant is always audit-ready and risk-mitigated.
Food Processing Plant Design
Collabtec applies process flow optimization, layout engineering, and zoning principles to deliver hygienic and efficient food processing plant design. We conduct:
- Material and Personnel Flow Mapping to separate raw and finished product movement.
- P&ID Development for all food-grade pipelines and utilities.
- Hygienic Architecture Design including coving, epoxy flooring, and non-porous wall finishes.
- Integration of CIP/SIP systems for in-place cleaning of food-contact equipment.
- Provision for Allergen Management Zones through pressure zoning and airflow control.
- Use of sanitary design principles per 3A and EHEDG standards.
- Line balancing and throughput analysis to avoid production bottlenecks.
Our design approach aligns with Codex Alimentarius, FSSAI, and ISO 22000 regulatory frameworks.
HACCP-Compliant Facilities
We build HACCP-compliant facilities through a risk-based approach to eliminate biological, chemical, and physical hazards:
- Identification of Critical Control Points (CCPs) and engineering them into the process flow.
- Use of FDA/EFSA-approved construction materials with traceability.
- Inclusion of modular drain systems with anti-backflow technology.
- Installation of Hygienic Zonal Segregation (white, grey, black zones).
- Implementation of real-time monitoring systems for CCPs with SCADA.
- HVAC design with HEPA filtration and air change rate control.
- Creation of positive pressure zones to prevent ingress of contaminants.
Our validation protocols cover HACCP Plans, risk registers, and CCP monitoring dashboards integrated into MES platforms.
Cleanroom Design
For high-hygiene segments like bakery additives, nutraceuticals, and dairy, we design ISO-classified cleanrooms using cGMP standards:
- Design of modular cleanroom panels using food-grade PUF or PIR cores with flush wall systems.
- Engineering of classified airlocks, anterooms, and clean corridors.
- Deployment of LAMINAR airflow modules, Terminal HEPA Filters (H14), and return air risers.
- Integration of BMS-controlled HVAC systems to maintain relative humidity, pressure differential, and particulate levels.
- Cleanability-focused furniture design, such as radius-edge SS304 work surfaces and autoclavable tools.
- Floor cove profiles and flush-mounted LED lighting for particle minimization.
We ensure compliance with ISO 14644, GMP Annex 1, and FDA cleanroom guidelines.
FSSAI-Compliant Facilities
Collabtec creates infrastructure ready for seamless FSSAI audit clearances, ensuring every element complies with Chapter 4 of FSSAI guidelines:
- Design of FSSAI-compliant kitchens and production lines with emphasis on cleanliness and traceability.
- Integration of pest control traps, fly-proof doors, and hand wash/foot dips in entry protocols.
- Water treatment and testing units as per IS 10500 for potable water usage.
- Documentation support including SSOPs, GHP guidelines, traceability records, and Recall Procedures.
- Preparation of Factory Layout with FSSAI Annotations, Hygiene Checklist Compliance, and Audit Flow Charting.
We act as a partner throughout the FSSAI application, infrastructure setup, and compliance certification process.
GMP Facility Design
We bring expertise in GMP facility layout, clean design engineering, and documentation aligned with WHO-GMP, Schedule M, and USFDA norms:
- Design with Unidirectional Personnel and Material Movement to prevent cross-contamination.
- Usage of validated construction materials (SS304/316, HPL, food-grade epoxy).
- HVAC systems with differential pressure zoning, 100% fresh air or recirculating air systems as per classified area.
- Validation protocols (DQ, IQ, OQ, PQ) and support during Process Qualification (PQ) phases.
- Engineering of AHUs with BMS Integration, and double skin panels with cleanable filters.
- Specification of cleanable ceiling systems, utility raceways, and pass boxes with interlocking doors.
We assist with complete documentation for GMP audits, including SOPs, logbooks, and training modules.
Turnkey Project Execution
Collabtec offers complete turnkey project execution from greenfield site development to plant handover:
- Site Master Planning including civil, structural, MEP, and zoning maps.
- FEED (Front End Engineering Design) and Detail Engineering with 3D BIM models.
- Procurement of GMP-compliant equipment, utilities, and MEP packages from approved vendors.
- Construction Management with Gantt Tracking, labor safety compliance, and work quality monitoring.
- Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) for critical equipment.
- Full handover package including As-Built Drawings, Compliance Dossier, and SOP Training.
Collabtec’s integrated EPCM (Engineering, Procurement, Construction & Management) model ensures control over cost, time, and quality.
Cold Storage Facilities
We design cold storage facilities and temperature-controlled warehouses tailored for FMCG perishables like dairy, frozen goods, and beverages:
- Use of pre-fabricated insulated panels (PIR/PUR) for walls and ceilings with low U-value.
- Installation of glycol chillers, refrigeration coils, and screw compressors with automation.
- Air curtains, auto-close dock doors, and dock shelters for thermal integrity.
- Racking system planning (FIFO, LIFO, High-Density) based on material handling logic.
- IoT-enabled temperature loggers with alert systems and backup power planning.
- Provision for blast freezer rooms, banana ripening chambers, and dual-temp zones.
All systems are built as per GWP, ASHRAE, and ISO 22000 cold chain standards.
Smart Manufacturing
In the era of Industry 4.0, Collabtec empowers FMCG factories with smart manufacturing capabilities:
- Deployment of SCADA, MES, and IIoT platforms for batch and line monitoring.
- Installation of PLC-driven process controls with HMI touch panels.
- Integration of barcode/RFID-based traceability and real-time dashboarding.
- Predictive maintenance setups using sensor analytics and AI-based alerts.
- Full digital documentation ecosystem with e-logbooks, e-SOPs, and audit trails.
Smart systems enable data-driven decisions, operational agility, and compliance traceability for the future-ready FMCG plant.
Packaging Lines
Our expertise spans primary, secondary, and tertiary packaging systems engineered for hygienic and high-speed output:
- Servo-driven filling and sealing machines integrated with sterilization tunnels (UV/Steam).
- Blister, bottle, pouch, and tray line layouts with minimal human contact design.
- Auto-labeling, coding, and rejection systems for quality assurance.
- Pick-and-place robots, conveyor logic design, and vision inspection systems.
- Cleanable SS enclosures and washable conveyor belts (PU/SS modular).
- Inline weight checks, metal detectors, and shrink wrapping systems.
We also ensure ergonomic layout, OEE monitoring systems, and quick changeover setups for maximum uptime.
Why Collabtec Stands Out in the FMCG Sector
1. Experience Across FMCG Verticals
From dairy to personal care, our diverse portfolio makes us the preferred partner.
2. End-to-End Service Model
Single-window execution reduces the burden of managing multiple vendors.
3. Global Certification Knowledge
We understand ISO, BRC, HACCP, FSSC, and local norms.
4. Focus on Hygiene & Safety by Design
Every detail, from drainage slope to material finish, is thought through.
5. On-Time Delivery and Transparent Communication
Our reputation is built on timely handovers and clear client collaboration.
Collabtec: Your Growth Partner in the FMCG Industry
The FMCG industry is evolving at an unprecedented pace. With stricter regulations, increasing consumer demands, and global competition, companies cannot afford to fall behind on infrastructure and operational compliance. Collabtec Design Build Pvt Ltd offers not just services, but partnerships for growth.
We provide a one-stop solution encompassing design, engineering, compliance, construction, validation, and documentation support. By partnering with us, your brand stands to benefit from a future-ready, certified, and competitive production environment.
Let Collabtec be the force behind your hygienic, efficient, and compliant FMCG operations.
