170M
Annual production capacity in liters
Enabling Efficient Greenfield Dairy Operations Through Production and Logistics Planning
EFESO supported a leading dairy producer with end-to-end production and intralogistics planning for a greenfield facility, defining functional layouts, material flows, and automation concepts to improve operational efficiency and enable scalable growth.
Food & Beverage
Cost and Value Engineering
Factory Planning
Manufacturing
Our Client
The client is a fast-growing dairy and juice producer expanding its footprint in the Middle East. To support long-term growth and secure operational excellence, the company launched a greenfield investment in Saudi Arabia, targeting a highly automated, scalable production site that meets the highest standards in hygiene, efficiency, and sustainability.
30K
Total factory footprint in m²
9
Filling lines covering >50 SKUs
The Challenge
To support its ambitious growth strategy, the client decided to invest in a new greenfield dairy and juice production site. The project required more than isolated production line design; it demanded a fully integrated production and intralogistics concept capable of aligning processing technology, material flows, automation, and operational zoning from the earliest planning stages. Key challenges included:
- High complexity of operations: The factory had to accommodate both dairy and juice processing, multiple packaging formats, and more than 50 SKUs, requiring independent yet synchronized production areas.
- Demand for automation: To remain competitive and ensure long-term efficiency, the client targeted maximum automation from filling to truck loading, including automated high-bay storage and AGV-based transport.
- Strict hygiene and zoning standards: Food safety requirements imposed clear separation of people, material, and waste flows, increasing layout and logistics complexity.
- Time-to-market pressure: The project timeline from planning to SOP was tight, leaving little margin for redesign or late-stage corrections.
- Investment efficiency: With a large CAPEX envelope, every design decision needed to balance performance, scalability, and cost efficiency.
The client therefore required a partner capable of defining an integrated production and intralogistics concept, ensuring operational feasibility, scalability, and smooth realization.
Real Results Achieved Together
Through EFESO’s integrated factory planning approach, the new greenfield dairy plant was designed as a highly automated, scalable production site that combines operational excellence with investment efficiency. The concept enabled a fast implementation timeline, optimized space usage, and a step-change in logistics performance while ensuring full compliance with hygiene and quality standards.
35%
Reduction in logistics headcount through automation
20%
Increase in space efficiency
25%
Faster time-to-market through integrated planning
Transformation Impact
- Designed a future-proof production concept based on process-flow diagrams and aligned technology selection across mixing, processing, filling, and packaging.
- Designed and tendered 9 high-speed filling lines for minimal staffing and maximum efficiency
- Implemented 100% automated product flow from filling to truck loading
- Delivered an I-structure factory layout with clear and lean flows, supporting long-term site expansion
- Reduced storage footprint by almost 50% through automated high-bay systems
- Achieved significant OPEX savings via reduced logistics labor and optimized transport technologies
Our Approach
EFESO supported the client with an end-to-end factory planning approach, covering all phases from strategy to SOP.
The engagement started with pre-concept validation and concept design, where production, logistics, and building requirements were consolidated into a scalable and future-proof masterplan. This ensured a robust production concept aligned with process flows and technology requirements across the entire value chain.
In the next phase, EFESO led the CAPEX optimization, combining benchmark-based cost estimation with targeted design alternatives to maximize investment efficiency.
During detailed process and logistics design, the team developed:
- Full processing concepts for dairy and juice lines
- Automated intralogistics solutions for raw materials and finished goods
- BIM-based equipment layouts and utilities specifications
Finally, EFESO provided tendering and realization support, ensuring that quality, cost, and timeline targets were safeguarded throughout implementation.
This integrated, cross-disciplinary methodology enabled the client to move from concept to operation with a fully aligned factory system covering technology, people flows, material flows, and building design in one coherent solution.
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Ready to Build your Next Factory for Performance and Growth?
- Planning a greenfield or brownfield factory and need an integrated concept from strategy to SOP?
- Looking to maximize automation while keeping CAPEX under control?
- Aiming to design future-proof production and logistics flows that scale with your business?
Get in touch with EFESO to turn your factory vision into measurable operational results.
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