Aseptic Carton Manufacturing Facility Delivered for SIG Combibloc

HORIZON INDUSTRIAL PARKS’ SOLUTION: THE KEY HIGHLIGHTS

● Strategic and Well-Connected Location
SIG’s new manufacturing facility is situated in Horizon Industrial Park Bhayala near Ahmedabad, Gujarat. Located along the Ahmedabad-Rajkot Highway, the park is well connected to the Western Dedicated Freight Corridor (WDFC) which will link the states along its length from Delhi-NCR to Mumbai’s JNPT to the State of Gujarat. The facility is ~45 kms from Ahmedabad and located near the well-established industrial cluster at Sanand (~33 kms), which hosts more than 500 well-known companies from auto, auto components, engineering, pharmaceuticals, FMCG, and F&B sectors. Furthermore, it is strategically positioned close to some of the major customers for SIG’s aseptic packaging solutions.

● Adherence to the Stipulated Timeframe
Horizon completed the Phase I, which includes the external infrastructure, landscape and the utility services successfully as per the agreed timeline. The dry access for this built-to-suit facility was provided to SIG at the 9-month mark, and the final handover was given at the 12-month mark, ensuring that all milestones were met as committed.

● Compliance with Local Regulations
In addition to the park’s strategic location, SIG also chose Horizon Industrial Parks for its demonstrated commitment to compliance and adherence to local, state, and national regulations for each of their past and ongoing projects.
All design parameters ensured compliance to LEED Gold certification criteria for the project, and met established standards for environmental sustainability, energy efficiency, and responsible construction practices.
The SIG facility at Bhayala also fulfils all statutory and standard approvals necessary for manufacturing and storage.

● Efficient Design and Layout
Each feature of the SIG facility demonstrates a high level of efficiency and adaptability, supporting seamless, independent operations and ensuring the facility is resilient, scalable, and aligned with complex operational demands.

• The main plant building features large clear spans with no interior columns: 50 meters for the printing hall, 33 meters for the production and finishing halls, and 30 meters for the warehouse area, providing open, flexible spaces.
• The clear height is 12 meters throughout the entire structure, with a specific storage area for heavy-duty print reel cylinder racks having 18 meters of clear height.
• Pile foundations are used to support the massive loads from the reel cylinder storage racks.
• Machine foundations include embedded steel rails in the floor above RCC foundations, with 100mm sunk floor slabs for specific machine profiles and high-performance chemical grouts used after machine installations.
• A heavy-duty mezzanine with a load-bearing capacity of 3 KN/square meter is designed for transformers, chillers, pumps, compressors, pressure vessels, and switchgear panels.
• The G+1 RCC canteen building is connected via an overhead bridge to the office area on the mezzanine floor of the main plant, ensuring easy access between the two spaces.
• The electrical power required for Phase-I operations is 4 MVA, supplied by two 2.5 MVA transformers rated at 400 V. General lighting and electrical cabling are set up with feeder panels for each zone according to functional needs.
• A water-cooled HVAC system, with 1,860 TR capacity (four 465 TR VFD-driven screw-type chillers), is designed to handle machine exhaust and provide cooling for the shop floor, office areas, electrical rooms, and the canteen.
• A mechanical ventilation system and 24-foot diameter HVLS fans are provided for the warehouse area.
• The main HVAC system also includes a 100 TR chiller capacity for process cooling, using a plate heat exchanger.
• Four VFD-driven cooling towers, each with a 400 M3/hr capacity, are installed on the roof. An RO plant and softener equipment are provided to treat water and use it for the cooling towers in the HVAC system.
• The system includes one 435 CFM VFD-driven screw-type oil-free compressor and two 435 CFM fixed screw-type oil-free compressors, all rated at 8.0 kg/cm², along with air-cooled refrigerant-type air dryers and a 4m³ dry air receiver.
• The facility includes an LPG gas bank with a vaporizer, distribution system, and pressure-reducing stations on the shop floor and in the canteen’s wet kitchen.
• Utility piping is installed throughout the plant, with tap-off points at floor level based on user requirements.
• Acoustic enclosures are installed in part of the production area to absorb noise and limit sound levels to 70 dB outside, from the 110 dB noise produced by the machines inside.
• An integrated IBMS (Integrated Building Management System) is used for real-time monitoring of all MEP (Mechanical, Electrical, and Plumbing) services to ensure high operational efficiency.

Phase1 of SIG’s manufacturing plant

● ESG-Compliant Manufacturing Unit
Horizon’s approach to ESG compliance in its facility design, material selection and advanced construction practises emphasise energy efficiency, water conservation, and reduced reliance on non-renewable resources:

• The facility is designed with space and structural provisions to accommodate future rooftop solar installations, aiming to harness renewable energy to reduce carbon footprint.
• Rooftop skylights maximise the use of natural daylight, which lowers daytime electricity consumption.
• High COP (>5.67, as per AHRI) VFD driven screw type chillers to reduce energy consumption and at par with LEED standards for sustainable design.
• All air handling units (AHUs) are equipped with VFD motors for the HVAC system, which adjust speed based on demand, making them energy efficient. 50% of the total capacity of air compressors are also VFD driven for further energy efficiency.
• 30% of the total plot as open area with 25% vegetation cover as per LEED requirement promoting ecological balance in the micro-environment.
• Rainwater harvesting system is installed with a retention pond at the end of the storm water drain system for thorough collection and disposal. This can be reused for other non-potable uses in the facility, reducing dependence on freshwater.
• Use of low flow fixtures promotes an optimal use of water, and a dual plumbing system separates water lines for flushing and domestic use. The recycled, treated water is used for toilets and irrigation, further reducing freshwater demand by means of an MBBR type STP.
• The evaporator plant uses a ZLD system to treat rejected water (such as from the RO) for maximum recovery of water from waste. The rejected water is re-used for cooling towers for the HVAC system reducing the overall water consumption.
• LED lighting fixtures have been installed throughout the facility to meet optimised lux levels for general lighting and minimise energy consumption.