Belcolade, a global player in authentic Belgian premium chocolate, commissioned us at the beginning of 2021 to design the utilities for the expansion of their factory in Erembodegem. At the same time, we were challenged to transform the entire factory into a CO₂-neutral site.
Let’s get to work!
We immediately started designing the new central utilities building, distributing all utilities to the consumers in the new building, and converting the existing production facilities. Our responsibilities included:
🔧 P&ID and Concept Design Together with Cenerpro, we designed a complete system consisting of heat pumps, cooling towers, and an e-boiler to supply five temperature networks forming the backbone of both the new and existing factory. We also designed the compressed air generation, water treatment, wastewater processing, and domestic hot water systems.
🏗️ 3D Design and Layout We designed the utilities building, including machines, pipe racks, MCC rooms, tank farm, platforms, and steel structures, with a focus on ergonomics, accessibility, and safety.
🧱 BIM Model and Coordination The entire design was modeled in 3D. Through BIM, we created a coordination model that was reviewed weekly with the client and later with suppliers. We ensured the model was always up to date, evolving from basic engineering to construction models, and ultimately to an as-built model of the entire factory.
📐 Engineering Our project engineers calculated all piping circuits for pressure loss and flexibility. We also designed and calculated steel structures for platforms, pipe racks, skids, and other components.
🛒 Procurement We prepared 3D models, plans, isometrics, bills of quantities, and specifications, and conducted price inquiries and comparisons for the purchase of all necessary components and installations.
🏗️ Construction management After tendering, we ensured that each supplier executed the design correctly and adhered to the agreed timeline. Every model and construction drawing was checked for compliance with the design.
📅 Site management and planning Our project manager coordinated the entire execution schedule – not only for utilities but also for process, civil, and electrical/automation – to ensure a timely start-up.
👷♂️ Site management and supervision Two of our site supervisors were permanently present on-site for daily follow-up and organization. They worked closely with our project engineers, who monitored and adjusted the technical execution as needed.
🚀 Start-Up Finally, we were responsible for filling the systems and assisting with the start-up of all utilities.
The Challenges
There’s no doubt this project was a challenge. Not only did we start in the middle of the COVID period, but it was also a technical and planning feat.
- COVID: The project began during the lockdown, making physical meetings with the client and suppliers impossible. Thanks to a quick switch to Teams and video conferencing, we were able to start smoothly.
- Tight Deadline: The new factory had to be operational on time. We focused on constructing the utilities building and connecting it to the new line, with the option to later connect the existing factory without downtime.
- Prefab Piping: We even assisted in the engineering of process piping, pipe racks, and steel structures. By pre-constructing pipe racks including piping, piping companies could start before the building was completed – saving valuable time.
- Daily Adjustments: The project schedule required daily adjustments to perfectly align the various suppliers.
- Conversion of Existing Factory: We identified all users and switched them over to the new network one by one, with minimal impact on production.
- Backbone via the Roof: Since the existing utilities had to remain operational until the switch, we routed the new backbone over the roof. This allowed us to enter through technical rooms and install new piping alongside the existing ones. After the switch, the old piping was removed.
Some facts
- Over 8 km of piping was installed for the utilities backbone.
- More than 80 pumps were installed for circulation, generation, and heat recovery.
- Over 4 MW of thermal capacity was installed via heat pumps and other generators, efficiently redistributing heat throughout the plant.
- The design concentrated all pumps, valves, instrumentation, and other equipment on ergonomically accessible skids, eliminating the need for aerial work platforms.
- Almost all make-up water for the cooling towers comes from recovered rainwater, collected from roofs and pavements and stored in underground buffers of over 2,000 m³.
- The Belcolade factory in Erembodegem is now the first CO₂-neutral chocolate factory in the world!
Proud!
- We are incredibly proud of our team and their achievement.
- We thank our client Belcolade for their trust and the opportunity to contribute to this unique project.
#demagroup #team #utiliteiten #engineering #design #management
