Services

Factory and production planning

We plan new food production facilities, support expansions and improve existing production processes. You can commission us for the whole project or for individual tasks.

Factory and production planning

From the initial idea to ongoing operations

The six phases outline a complete project. We also take on individual tasks and join projects with existing plans.

Phase A · Steps 0 – 2

Idea and feasibility

Idea workshop, baseline data and capacity calculations, feasibility study including economic viability.
  1. Step 0

    Idea development

    In a one- to two-day workshop with management, we clarify the product range, market, production targets and investment budget. We define the objectives and what is explicitly outside the scope, and analyse products and quantities.

    Deliverable: A documented brief with objectives, strategic decisions and quantities for each product and product group.

  2. Step 1

    Baseline data collection and capacity calculation

    We record product groups, quantities, shift patterns and growth scenarios, then calculate capacity for each process step and positions for ripening, chilling, storage and buffers. We audit existing plants and compare their performance indicators with benchmarks.

    Deliverable: Capacity and storage-position calculations, contextualised benchmarks and an audit report with recommendations for existing plants.

  3. Step 2

    Feasibility study and economic viability

    We assess space requirements, departmental arrangements and alternatives, automation levels, staffing, operating costs and economic viability, including return on investment. Market and competitor analysis informs positioning. We also define the project organisation and the roadmap to commissioning.

    Deliverable: A feasibility study comparing alternatives, assessing the market and estimating costs by category (target accuracy ±20%); an outline concept for supplier discussions, milestone schedule and project organisation chart.

Phase B · Steps 3 – 8

Concept and master plan

Production concept, goods and personnel flows, hygiene zones and equipment definition. The phase concludes with the master plan.
  1. Step 3

    Production concept

    We clarify the brief using the existing plans and develop the production processes, material and personnel flows, and hygiene concept.

    Deliverable: An explanatory report on the brief and a process description with a process flow diagram.

  2. Step 4

    Goods flow analysis

    We calculate routes and quantities for raw materials, semi-finished and finished products, packaging and dispatch. Internal logistics, warehouse management and control points are coordinated accordingly.

    Deliverable: Material-flow calculations, an internal logistics and storage concept, and an I-point plan describing the control points.

  3. Step 5

    Personnel flow planning

    We plan changing rooms, hygiene barriers, staff facilities and visitor routes, and determine staffing requirements by task and qualification.

    Deliverable: A staffing requirements schedule and personnel-flow plan.

  4. Step 6

    Hygiene zone planning

    We distinguish between low-hygiene, clean, high-hygiene and cleanroom areas and account for allergen management. Cleanroom equipment is examined as part of the concept.

    Deliverable: Hygiene zoning and a preliminary design study for cleanroom equipment.

  5. Step 7

    Equipment definition

    We size capacities and machines, position equipment with room for expansion, and assess partial or full automation, including robotics and conveyors.

    Deliverable: Capacity calculations, a layout sketch, a machine list with technical data, and an automation concept assessing benefits and economic viability.

  6. Step 8

    Master planning

    We bring rooms, product flows, quantities and expansion areas together in the factory layout, accounting for energy supply, logistics and infrastructure.

    Deliverable: A spatial concept as a DWG drawing and a budget cost breakdown based on the defined scope boundaries (target accuracy ±20%).

Phase C · Steps 9 – 11

Preliminary and detailed design

Design suitable for approval, support with the building permit application and detailed design with the architect and specialist designers.
  1. Step 9

    Preliminary design

    We develop the room schedule, utilities, equipment positions and circulation routes. Machine layout, line capacities, internal logistics and automation are detailed, and product, personnel and waste-flow plans are updated.

    Deliverable: A 1:100 machine layout in DWG and PDF with positions and I-points, performance data sheets, detailed internal logistics plans, operating specifications and an agreed automation solution; updated flow plans and budget costs with target accuracy ±10%.

  2. Step 10

    Support with the building permit application and coordination with authorities

    We contribute to permit documents and coordination with building, trade and food authorities. Quality assurance, cleaning, hygiene and waste-management concepts, the IT/ERP concept and pest-control plan are coordinated. Submission and responsibility for it remain with the authorised planner.

    Deliverable: Contributions to the building permit application, coordinated concepts and records of outcomes from authority meetings, with specialist support and the machine layout.

  3. Step 11

    Detailed design with the architect and specialist designers

    We coordinate construction-ready plans with architects and specialists in structural engineering, building services, electrical systems, building physics and fire protection. Doors, windows and utility connections are coordinated with production.

    Deliverable: An agreed interface plan covering the building, specialist designs and production equipment.

Phase D · Steps 12 – 15

Options, contract award and project control

Comparison of options, requirements specification, tender evaluation and award, project management.
  1. Step 12

    Comparison of options

    We compare alternatives by investment and operating costs, staffing requirements and benefits.

    Deliverable: A transparent comparison of alternatives as the basis for further selection.

  2. Step 13

    Preparation of requirements specifications

    We define technical requirements, performance, interfaces and acceptance criteria. For equipment, high-bay storage, conveyors and cleanrooms, we determine quantities and update drawings.

    Deliverable: A requirements specification, the basis for the schedule of works, and 1:100 equipment drawings in DWG at tender stage.

  3. Step 14

    Tendering, evaluation and contract award

    We compare international suppliers by technology, economic viability, energy, service and references. Machinery, internal logistics and cleanroom technology undergo specialist assessment.

    Deliverable: An evaluation matrix comparing suppliers and recommending contract awards, plus assessment reports for each discipline.

  4. Step 15

    Project management

    We manage schedules and costs, review the project plan and coordinate participants. Installation dependencies and ERP interfaces are included in planning; ongoing advice is documented in writing.

    Deliverable: A reviewed project and installation schedule with critical path, dependencies and interface requirements, plus weekly status reports and written recommendations throughout the project.

Phase E · Steps 16 – 17

Engineering and logistics

Detailed engineering, delivery and positioning, intralogistics up to IP69K.
  1. Step 16

    Detailed engineering

    We detail utility lists, connection points, the layout and interfaces, coordinating them with building-services planners.

    Deliverable: Detailed engineering with agreed interfaces and documented building-services coordination.

  2. Step 17

    Machinery delivery and positioning

    We plan machine transport and placement, as well as internal logistics from manual to fully automated IP69K solutions. On site, we monitor equipment installation against workmanship requirements, working drawings and schedules.

    Deliverable: Transport and equipment-placement concepts and inspection reports for each site visit covering equipment installation.

Phase F · Steps 18 – 24

Acceptance, ramp-up and operation

Acceptance testing at the manufacturer and on site, trial operation, commissioning, training and support during ongoing operations.
  1. Step 18

    FAT support

    We support acceptance at the manufacturer’s premises against agreed test criteria, record the results and assist with defect management.

    Deliverable: Support for supplier acceptance testing with an acceptance record.

  2. Step 19

    SAT support

    On site, we check machine and equipment functions, the readiness of internal logistics and the operability of cleanroom technology.

    Deliverable: Technical acceptance records with functional checks and performance evidence.

  3. Step 20

    Trial operation

    We support trial operation and production trials and work on the necessary improvements.

    Deliverable: Processes checked during trial operation in preparation for production start-up.

  4. Step 21

    Commissioning

    We support ramp-up, product launches and performance tests through to the first delivery.

    Deliverable: Commissioning support throughout start-up, with a final report.

  5. Step 22

    Training

    We train operators, shift supervisors, maintenance staff and quality-management personnel.

    Deliverable: Training for the functions involved in operating production.

  6. Step 23

    Hygiene, HACCP and certification

    We work on hygiene, waste and cleaning concepts, HACCP, traceability and digitalisation, and support certification preparation and audits.

    Deliverable: Agreed operating concepts and support with certification preparation and audits.

  7. Step 24

    Project check

    We review existing plans or plans prepared by others, either in full, in part or on specific points. This review is also available independently of an overall project and before contract award.

    Deliverable: A review report with specific improvement measures.

Range of services

Services by discipline

Strategy & master planning

Feasibility and a cost estimate with ±20% accuracy before the investment decision. The economic assessment considers staffing, energy and maintenance over the operating life as well as the investment.

  • Preliminary designs and feasibility studies
  • Site development and factory structure planning
  • Capacity and expansion planning
  • Master planning
Process planning

Defines capacities and processes before equipment is purchased. Ripening, thermal processing and cooling are sized for planned volumes to preserve recipes and product quality.

  • Production and process engineering
  • Process flow analysis
  • Process flow diagrams
  • Performance and capacity calculations
  • Optimisation of existing production processes
Factory & layout planning

A 1:100 layout showing routes, areas and expansion stages.

  • Layout planning at 1:100 scale
  • Spatial and functional concepts
  • Expansion areas and development stages
Technology & machinery concepts

A machinery list with technical data, sized for the product and production volume.

  • Machinery lists with technical data
  • Technical specifications
Automation & digitalisation

We determine the level of automation according to staffing requirements, product quality and economic viability.

  • Automation concepts
  • Definition of machinery automation
  • Interface concepts
  • Production data concepts
  • Digitalisation of production processes
  • Support with SCADA and control system concepts
Intralogistics & material flow

Separate goods, personnel and waste flows, with less manual transport.

  • Goods flow planning
  • Personnel flow planning
  • Waste flow planning
  • Internal transport concepts
  • Storage and buffer concepts
  • Material flow optimisation
Personnel & organisation

Staffing requirements, shifts and deployment planning reflect qualifications and availability at the site.

  • Staffing requirement calculations
  • Organisational concepts
  • Staff qualification requirements
  • Resource planning
  • Operational organisation planning
Hygiene & certification

Hygiene zones, HACCP and certification considered from the planning stage.

  • Hygiene zone planning
  • Cleaning and waste management concepts
  • HACCP support
  • Preparation for certification
  • Support during audits
Tendering & procurement

Requirements specification, bid comparison and award recommendation.

  • Preparation of requirements specifications
  • Technical specifications
  • Tender management
  • Bid comparison and award recommendations
  • Supplier selection and procurement support
Project management & implementation

A schedule with a critical path and weekly status reports.

  • Project control and coordination
  • Schedule management and project monitoring
  • Coordination of international project teams
  • Building and infrastructure coordination
  • Coordination with architects and specialist designers
  • Utility connections and infrastructure planning
  • Coordination of interfaces between production and the building
Commissioning & optimisation

Support from FAT to target output, with performance verification.

  • Production start-up support
  • Performance verification
  • Optimisation programmes
  • Support with capacity expansions
Project check & design review

A review report with measures to take before contract award or the start of construction.

  • Full, partial or targeted review of developed projects
  • Report with specific improvement measures

Optimisation and review

Improving existing plants and plans

Process optimisation during ongoing production

Cutting, the pre-packed retail products department and packaging: specification templates, daily yield checks, goods flow, portioning, staffing plans and training. A LuCo consultant works at the plant for individual days or on a continuous basis. Targets are agreed jointly for each project in advance, for example cutting output, yield and the proportion of trimmed cuts, and verified monthly.

Deliverable

Monthly status reports on target achievement, a final report and, on request, a new layout drawing with an updated equipment list.

External benchmarking

Your performance and quality data compared with operations in Europe. First, indicators are collected and analysed; on request, this is followed by on-site verification with your team and an assessment of the effects after two months.

Deliverable

Benchmark analysis presented as slides, written recommendations and a list of measures with priorities and a schedule.

Project check & design review

We review existing plans or plans prepared by others, either in full, in part or on specific points. This review is also available independently of an overall project and before contract award.

Deliverable

A review report with specific improvement measures.

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