abcd ef co-eng/a&c co-eng / a&c manufacturing buildings introduction january 2013

CO-Eng/A&CCO-Eng/A&C

CO-Eng / A&CCO-Eng / A&C

Manufacturing Buildings

IntroductionJanuary 2013


Design Principles for Manufacturing Buildings

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•Where feasible group several small building volumes into one bigger building with simple shape, regular building grid and consolidated roofline.

•Establish clear hygienic zoning. Group rooms with similar indoor requirements where possible. All elements fit for cleaning and maintenance.

•Ensure safe circulation on site by separating people and traffic flow and providing comprehensive signage.

•Provide safe and healthy workplaces. This is Nestlé policy and important to achieve environmental labels like LEED (US Green Building Council).

•Conceptually integrate building structure & envelope with technical services of the building, including building related industrial services elements.


Layout Design

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• Where possible, group several small building volumes into one bigger building with shape in a simple and modular grid.

• Strive for compact buildings with simple shapes and rooflines; avoiding complex building agglomerations.

L-flow type factory

gravity or fluid type factory (powder handling)

U-flow type factory

Linear-flow type factory

industrial

services

prod. 2

finished goods warehouse

prod. 1extensio

n

raw materials reception

multi product – back bone type

Tower-like Egron and adjacent process buildings

Large span single-storey buildings

for packing, warehousing and can manufacturing

Flow of Manufacturing Process Example Konolfingen

Matching Flow Sheets and Buildings


Our buildings have to be designed and constructed to guarantee that control, to protect our people and products from those hazards

Hygienic Design & Construction of food processing buildings, including appropriate zoning, allows the right flows of raw & packaging materials, finished goods, wastes and personnel in an environment designed to control potential contamination from micro-organism, allergens and other hazards.

•Establish clear hygienic zoning based on the process flow sheets.

•Identify space needs per functions and define their relations.

•Define indoor conditions like temperature/humidity, floor finishes, drains, wall finishes etc.

Hygienic Zoning

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Example


Building Volumes and Composition

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Harmonizing Building Volumes, showing tower buildings as separate volumes.

The most effective architectural approach to reduce the CO2 footprint due to the grey energy embedded in construction materials is to make buildings compact, with simple shape and with a building shell that is suitable for the local climatic

conditions.

Puelche, Chile

Example

CO-Eng/A&CCO-Eng/A&C Building Shell

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• Building skins should respond to the local conditions, to the physics/dynamics of the building, to comfort and interior well-being of the building users.

• Strive for flush facade surfaces without apparent structure. Openings only where absolutely required (workplaces, orientation).

• Screens (e.g. from stretch metal) can be used to consolidate small building units of different type and technical installations into a homogenous simple building volume.

• Consider day and night effects and harmonize Building Volumes.


Building Structure

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• Foresee future expansions and changes/increases of equipment for waiting beams or columns.

• Consider equipment loads and vibration for the structural calculation. Concrete structures can crack and bolts in steel structure can become loose.

• Conceptually integrate building structure & envelope with technical services of the building, including building related industrial services elements. Optimize for short ducting & piping, preferably without cladding; building and equipment are closely linked. Provide wall and ceiling penetrations for piping and ducting properly sealed.

Konolfingen,

Switzerland

Konolfingen,

Switzerland


Choice of Materials and Finishes

SIKA MEMBERS AREA It is an information platform which contains approved Sika Solutions according to Nestlé’s requirements for different production areas. 8

• Prefer easy to clean and easy to maintain materials for platforms, stairs, ladders such as stainless steel.

• Good quality water-based paint is preferred over solvent-based because solvents may release Volatile Organic Compounds (`VOC`s`) with toxic impact on the environment and enhancement the buildup of moulds.

• Electrically conductive floor in explosive areas (dust explosion) is recommended.

• Resin based coatings such epoxy.

Advantages: smooth, easy to clean finish, resistant to chemicals with the right additives, fast to install.

Disadvantages: requires skilled people to install it, no slopes possible, more expensive per sq. meter

• Flooring solutions should balance between easy to clean and non slip finish for safe working conditions.


Signage

Verify that the colors are not in conflict with local laws and standards. 9

• Ensure safe circulation on site by separating people and traffic flow and providing comprehensive signage.

• Clearly mark emergency exits, use also coloring and graphics to direct people and traffic flow.

Color Zone name Color nameNCS code

(Natural Color System)Stripe

dimension

High hygiene dry zone Yellow NCS S 0540 Y 50 cm

High hygiene dry probiotic zone Yellow NCS S 0540 Y 50 cm

Yellow NCS S 0540 Y 45 cm

Blue stripe NCS S 1040 B 5 cm

Medium hygiene dry zone Orange NCS S 0540 Y 50 R 50 cm

Medium hygiene wet zone blue NCS S 1040 B 50cm

Basic hygiene dry zone Green NCS S 1040 G 50cm

High hygiene controlled wet zone

Color Identification in Hygiene Zones

Color identification stripes are mandatory at wall in hygienic transition areas: personal lock, material lock, and rooms connected to them.Color identification stripes are optional inside hygienic zone: i.e. process room, corridors, staircase.


Security, Safety and Health

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• Wide doors allow to remove equipment for maintenance to the workshop easier.

• Prefer fixed platforms to access manholes in equipment instead building a scaffolding for every inspection or maintenance procedure.

• Ensure safe access to roofs. Install safe inspection and maintenance access when necessary and walkways protected with barriers.

• Control Room must have good visibility to the process area, with proper ergonomics and lighting design for good working environment. Producing highly sensitive Nestlé products requires full attention of the operators and to the workplace environment.


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abcd ef co-eng/a&c co-eng / a&c manufacturing buildings introduction january 2013

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