BEVERAGE DESIGN LAYOUT OVERVIEW

A beverage industry design involves a structured layout and workflow that optimizes production
from raw materials to finished goods, ensuring efficiency and quality. It incorporates key
elements like manufacturing processes, packaging, quality control, and safety measures to meet
regulatory standards and customer demands..

Overview of the key components and considerations in a beverage factory layout:

I. Core Production Zones (Following the Process Flow)

1. Raw Material Handling and Storage:

o Receiving Area: Dedicated space for receiving ingredients (water, sugar,
concentrates, packaging materials, etc.).
o Storage Facilities: Warehouses or silos for different raw materials. This includes
temperature-controlled environments for perishable ingredients (e.g., fruit purees,
dairy).
o Ingredient Preparation: Areas for tasks like water purification, sugar dissolving,
or fruit processing before mixing.
2. Processing and Mixing:
o Mixing Tanks/Vats: Where ingredients are precisely measured, blended, and
sometimes heated or cooled.
o Homogenization: For creamy or emulsion-based beverages to create a smooth,
stable texture.
o Filtration/Clarification: To remove impurities and improve product clarity.
o Pasteurization/Sterilization: Heat treatment (e.g., HTST, UHT, tunnel
pasteurization) to kill microorganisms and extend shelf life.
o Carbonation (if applicable): Equipment for adding carbon dioxide to sparkling
beverages.
3. Filling and Sealing:
o Container Rinsing/Sanitization: Machines to clean bottles, cans, or other
containers before filling.
 o Filling Lines: Automated machinery that fills containers with the beverage.
Different fillers exist for various beverage types (still, carbonated, viscous) and
container materials (glass, PET, cans, pouches).
o Sealing/Capping Machines: Immediately seal the filled containers to prevent
contamination and preserve product integrity. This often includes tamper-evident
seals.
4. Packaging:
o Labeling Machines: Apply labels with product information, branding, and expiry
dates.
o Secondary Packaging: Machines for bundling, shrink-wrapping, or placing
individual products into cases or cartons.
o Palletizing: Automated systems to stack and secure finished goods onto pallets
for storage and distribution.
5. Quality Control and Testing:
o Integrated points throughout the process for quality checks (e.g., pH, Brix,
microbiological analysis, sensory testing).
o Dedicated lab areas for more in-depth testing.
6. Warehousing and Distribution:
o Finished Goods Storage: Temperature-controlled warehouses for storing the
packaged beverages.
o Loading Docks: Areas for efficient loading of products onto trucks for
distribution.

II. Supporting Areas and Infrastructure

 Utility Rooms: Housing essential equipment like chillers, boilers, air compressors, and
electrical panels.
 Wastewater Treatment: Systems for treating wastewater generated during production to
meet environmental regulations.
 CIP (Clean-in-Place) Systems: Automated cleaning systems for tanks, pipes, and
processing equipment without disassembly, crucial for hygiene.
 Maintenance and Workshop Area: For equipment repair and upkeep.
  Office Space: Administrative offices, meeting rooms, and staff facilities.
 Locker Rooms and Restrooms: For employee comfort and hygiene.
 Security and Access Control: Systems to manage entry and exit, especially for sensitive
areas.

III. Key Layout Principles and Considerations

 Flow Optimization (Linear or U-shaped):

o Minimizing Movement: Design the layout to ensure a smooth, unidirectional
flow of materials and products, reducing unnecessary travel distances and
backtracking. This lowers material handling costs and improves efficiency.
o Reducing Bottlenecks: Identify potential choke points in the production line and
design the layout to ensure sufficient capacity and smooth transitions between
stages.
 Ergonomics and Worker Comfort:
o Workstation Design: Adjustable work surfaces, proper lighting, anti-fatigue
mats, and comfortable seating to minimize physical strain.
o Tool and Equipment Placement: Tools and controls should be within easy
reach, reducing repetitive or awkward movements.
o Material Handling Aids: Use conveyors, hoists, and other mechanical aids to
reduce manual lifting and carrying.
o Clear Pathways: Wide, unobstructed aisles for safe movement of personnel and
equipment.
o Environmental Control: Managing temperature, noise, and ventilation for a
comfortable and safe working environment.
 Hygiene and Sanitation:
o Segregation of Zones: Clear separation of "clean" and "dirty" areas to prevent
cross-contamination (e.g., raw material handling separate from finished goods).
o Easy-to-Clean Surfaces: Use of food-grade, smooth, and non-absorbent
materials for floors, walls, and equipment.
o Adequate Drainage: Sloped floors and proper drainage systems to facilitate
cleaning and prevent water accumulation.
 o Pest Control: Measures to prevent pests from entering the facility.
 Flexibility and Scalability:
o Design the layout with future expansion in mind, allowing for easy
reconfiguration or addition of new equipment and lines without major disruptions.
Modular structures are often preferred.
 Safety:
o Emergency exits, fire suppression systems, clear signage, and machine guarding.
o Design to minimize risks of spills, falls, and other accidents.
 Automation:
o Integrating automated systems for tasks like mixing, filling, packaging, and
palletizing can significantly improve efficiency, consistency, and reduce labor
costs.

Ergonomic Factors Considered: Minimizing Manual Material Handling

Manual material handling is a leading cause of workplace injuries, particularly in industries

involving repetitive tasks and heavy loads. For beverage production, this often translates to:

 Repetitive Strain Injuries (RSIs): From constant lifting, carrying, twisting, or pushing.
 Back Pain: Especially from lifting heavy raw material bags (e.g., sugar, bulk flavorings)
or cases of finished products.
 Musculoskeletal Disorders (MSDs): A broader category encompassing injuries to
muscles, nerves, tendons, joints, cartilage, and spinal discs.

By actively minimizing manual material handling, you directly address these risks, leading to a healthier
workforce and, consequently, improved productivity due to fewer sick days, reduced compensation
claims, and higher morale.
Figure 1.1: Factory floor Layout design

Source: Google Images, 2025

To achieve this critical ergonomic goal, the layout should strategically integrate various mechanical and
automated solutions:

1 Use Conveyors:

 Application: Ideal for transporting bottles, cans, caps, labels, and individual packaged
units between different stages of the production line (e.g., from de-palletizer to rinser,
from filler to labeler, from labeler to secondary packaging).
 Types: Belt conveyors, roller conveyors, chain conveyors, and air conveyors (for
lightweight plastic bottles) are all common. The choice depends on the product, speed,
and distance.
 Ergonomic Benefit: Eliminates the need for workers to carry items over distances or lift
them onto the next machine, significantly reducing repetitive movements and strain.

2. Automated Guided Vehicles (AGVs):

 Application: Excellent for transporting heavy raw materials from storage to the
processing area, moving empty pallets, or transferring finished goods from the packaging
line to the warehouse.
 Benefit: Fully automates the movement of bulk items, removing workers from tasks
involving heavy lifting and long-distance hauling. They can follow predetermined paths
or use advanced navigation systems.
 Integration: Requires clear, unobstructed pathways within the factory layout.

3. Forklifts and Pallet Jacks:

 Application: Indispensable for loading and unloading trucks, moving pallets of raw
materials within storage, and transporting stacked finished goods.
 Benefit: Allows one operator to move significant weight with minimal physical exertion.
 Considerations: Requires trained operators, designated traffic lanes, and sufficient aisle
widths in the layout for safe maneuverability. Electric forklifts are preferred for indoor
use to reduce emissions and noise.
4. Position Materials at Waist Height to Reduce Bending or Reaching:

 Loading/Unloading Stations: Design work surfaces, hoppers, or conveyor infeed points

so that workers are not constantly bending down to pick up items or reaching high above
their shoulders to place them. For instance, when loading empty bottles onto a conveyor,
the de-palletizer should bring layers of bottles to an ergonomic height.
 Ingredient Dosing Stations: For adding minor ingredients, ensure bins or containers are
elevated to an appropriate height, or use mechanical aids like scissor lifts to bring
ingredients to the worker.
 Pallet Dispensers/Stackers: Automated systems that present pallets at a consistent,
ergonomic height for loading or unloading.
 Tool and Component Storage: Organize frequently used tools and machine parts on
shelves or racks at eye-to-waist level.
 Ergonomic Benefit: Directly prevents awkward postures, reducing strain on the back,
shoulders, and neck. This is particularly important for repetitive tasks.

To effectively implement these solutions, the factory layout must consider:

 Dedicated Pathways: Ensure clear, wide aisles for AGVs and forklifts, separate from
pedestrian walkways where possible.
 Strategic Placement of Equipment: Position conveyors to seamlessly link sequential
production steps. Place material storage locations close to their point of use to minimize
transport distances, even with mechanical aids.
 Vertical Space Utilization: While horizontal movement is reduced, consider vertical
storage solutions (e.g., high-rack warehousing serviced by reach trucks) to optimize space
without increasing manual lifting.

Ergonomic Factors Considered: Workstation Design, Repetitive Motion

Reduction, and Environmental Control
These principles aim to create a work environment that minimizes physical stress on employees,
leading to fewer injuries, higher job satisfaction, and improved productivity.

I. Workstation Design:

The design of individual work areas is paramount for worker comfort and efficiency.

 Adjustable Workstations to Accommodate Workers of Different Heights:

o Application: This is especially critical in areas where manual intervention is still
required, such as quality checks, minor adjustments on machinery, or manual
packing of specialized orders.
o Implementation:
 Height-Adjustable Tables/Surfaces: Where possible, utilize tables or
platforms that can be raised or lowered (manual crank or electric motor) to
allow workers to work at an optimal height, whether standing or seated.
 Adjustable Chairs/Stools: For tasks that can be performed seated,
provide chairs with adjustable seat height, backrest, and armrests.
 Footrests: For shorter workers or those who are seated, provide footrests
to ensure proper leg and back support.
 Anti-Fatigue Mats for Workers Standing for Long Periods (e.g., in Filling or
Packaging Areas):
o Application: Essential in areas where workers spend significant time standing on
hard floors, such as at the start and end of filling lines, labeling stations, or
manual inspection points.
o Implementation:
 Strategic Placement: Install high-quality anti-fatigue mats in all areas
where prolonged standing is required.
 Material and Thickness: Choose mats made from durable, resilient
materials (e.g., rubber, PVC foam) with appropriate thickness to provide
cushioning and rebound.
 Maintenance: Ensure mats are regularly cleaned and maintained to
prevent slips and trips.
  Tools and Controls Within Easy Reach to Minimize Stretching or Twisting:
o Application: Applies to machine operators, quality control personnel, and
maintenance staff.
o Implementation:
 "Work Zone" Principle: Design workstations so that frequently used
tools, machine controls (buttons, levers, touchscreens), and components
are within the "normal reach envelope" (the area a worker can comfortably
reach without stretching or leaning). Less frequently used items can be
within the "maximum reach envelope."
 Ergonomic Tool Selection: Provide tools that are lightweight, well-
balanced, and have comfortable grips.
 Layout of Control Panels: Arrange control panels logically, with the
most frequently used controls prominently and centrally placed.
 Storage Solutions: Use tool holders, shelves, or drawers positioned
conveniently at the workstation.

II. Reduce Repetitive Motions:

Repetitive motions are a hallmark of assembly line work and a primary cause of RSIs.

 Automate Repetitive Tasks (e.g., Capping, Labeling) Where Possible:

o Application: Most beverage factories already do this for high-volume production,
but even for smaller scale operations or new lines, automation should be a
priority.
o Implementation:
 Robotics: Consider robotic arms for tasks like case packing, palletizing,
or even some specialized filling or assembly tasks.
 Automated Machinery: Invest in advanced filling, capping, labeling, and
packaging machines that require minimal manual intervention once set up.
 Sensor-Based Systems: Utilize sensors to monitor product flow and
trigger automated actions, reducing the need for constant human oversight
and manual adjustments.
  Rotate Workers Between Tasks to Prevent Repetitive Strain Injuries:
o Application: For tasks that cannot be fully automated or where human
intervention is necessary, job rotation is a critical administrative control.
o Implementation:
 Cross-Training: Train employees on multiple tasks within the production
process.
 Scheduled Rotation: Implement a formal schedule for rotating workers
through different workstations or tasks that use different muscle groups.
For example, a worker who was on a filling line might move to a quality
inspection station or a packaging area after a set period.
 Breaks: Ensure regular, short breaks are integrated into the work schedule
to allow for recovery.

III. Lighting and Noise Control:

Environmental factors directly impact worker comfort, safety, and performance.

 Bright, Uniform Lighting (400–500 lux) to Reduce Eye Strain in Inspection and
Quality Control Areas:
o Application: Critical for tasks requiring visual acuity, such as checking for label
alignment, fill levels, container integrity, or detecting foreign objects.
o Implementation:
 Lux Levels: Ensure illuminance levels meet or exceed the recommended
standards (400-500 lux is a good guideline for general factory tasks;
specific inspection points might require even higher, localized lighting).
 Uniformity: Avoid glare, shadows, and stark contrasts in lighting. Use
diffuse lighting sources and proper placement of luminaires.
 Color Rendering Index (CRI): Use light sources with a high CRI to
ensure accurate color perception, which is important for quality control.
 Task Lighting: Supplement general lighting with adjustable task lighting
for highly detailed visual tasks.
  Noise-Reducing Barriers or Ear Protection in High-Noise Areas (e.g., Near Filling
Machines):
o Application: Beverage factories can be very noisy due to machinery like fillers,
air compressors, conveyors, and blow molders.
o Implementation:
 Source Control: Prioritize reducing noise at its source through machine
maintenance, vibration dampening, and using quieter equipment where
possible.
 Noise Barriers/Enclosures: Install sound-absorbing panels or enclosures
around particularly noisy machinery (e.g., bottle rinsers, high-speed fillers,
air compressors).
 Layout Segregation: Locate high-noise machinery away from quiet zones
(e.g., offices, break rooms) if possible.
 Personal Protective Equipment (PPE): Provide mandatory hearing
protection (earplugs or earmuffs) in areas where noise levels exceed safe
limits (e.g., 85 dBA 8-hour TWA).
 Acoustic Treatment: Use sound-absorbing materials on walls and
ceilings in production areas.

Ergonomic Factors Considered: Worker Comfort and Safety

Climate Control (Ventilation, Cooling) to Maintain a Comfortable Temperature (20–24°C)

Given Heat from Machinery:

 The Challenge: Beverage production often involves machinery that generates significant
heat (e.g., pasteurizers, boilers, fillers, air compressors). This, combined with external
climate conditions (especially relevant in Onitsha, Nigeria, which can be hot and humid),
can lead to uncomfortable and potentially unsafe working conditions.
 Implementation Strategies in Layout:
o HVAC Systems: Design and install robust heating, ventilation, and air
conditioning (HVAC) systems capable of maintaining the target temperature
range (20–24°C or 68–75°F). This might involve:
  Centralized Air Conditioning: For large production halls.
 Evaporative Coolers: Can be effective in dry, hot climates, but less so in
humid ones like Onitsha.
 Spot Cooling: Directing cooled air to specific workstations where heat
exposure is highest.
o Ventilation and Exhaust Systems:
 Local Exhaust Ventilation (LEV): Capture heat and fumes directly at the
source (e.g., near boilers, processing tanks) and vent them outside.
 General Ventilation: Ensure adequate air changes per hour throughout
the facility to remove stale, hot air and introduce fresh air.
 Strategic Placement of Equipment: Where possible, locate heat-
generating machinery in areas with better ventilation or further from
constantly occupied workstations.
o Insulation: Insulate walls, roofs, and even machinery to reduce heat transfer into
the workspace.
o Monitoring: Install temperature and humidity sensors in key areas to ensure the
climate control systems are functioning effectively and to allow for adjustments.
 Ergonomic and Safety Benefit:
o Reduces Heat Stress: Prevents fatigue, dizziness, headaches, and more severe
heat-related illnesses (e.g., heat exhaustion, heat stroke).
o Improves Concentration: Workers are less distracted by discomfort, leading to
fewer errors and accidents.
o Boosts Productivity: Comfortable workers are more efficient and productive.
o Enhances Morale: Demonstrates a commitment to employee well-being,
fostering a positive work environment.

II. Clear Signage and Color-Coded Zones to Prevent Accidents and Improve Navigation:
 The Challenge: Large factories can be complex, with various processes, potential
hazards, and moving equipment. Clear visual cues are essential for safety and efficient
movement.
 Implementation Strategies in Layout:
o Safety Signage (OSHA/ISO Standards): Install internationally recognized
safety signs for:
 Hazards: "Caution: Wet Floor," "Warning: High Voltage," "Danger:
Confined Space."
 Mandatory PPE: "Eye Protection Required," "Hearing Protection
Required."
 Emergency Information: "Emergency Exit," "First Aid Station," "Fire
Extinguisher."
 Traffic Control: "Yield to Forklifts," "Pedestrian Crossing."
o Color-Coded Zones:
 Traffic Lanes: Use clear, brightly colored lines on the floor to delineate
forklift routes, pedestrian walkways, and emergency exits. For instance,
yellow for pedestrian aisles, white for storage, and red for fire-fighting
equipment.
 Hazard Zones: Use colors like red or orange to highlight areas with
specific hazards (e.g., pinch points, high-temperature surfaces).
 Production Stages: Different colors for raw material receiving,
processing, filling, packaging, and finished goods warehousing can
improve navigation and understanding of the flow.
 Equipment Status: Color-coding equipment (e.g., red for emergency stop
buttons, green for start buttons) or pipelines (e.g., blue for water, yellow
for gas) aids in quick identification and safe operation.
o Wayfinding Signage: Install directional signs to guide workers and visitors to
various departments, offices, restrooms, and break areas.
o Floor Markings: Use reflective tape or painted lines for clear pathways,
exclusion zones, and storage areas.
 Ergonomic and Safety Benefit:
 o Accident Prevention: Reduces the likelihood of collisions between pedestrians
and machinery, trips, falls, and exposure to hazards.
o Improved Situational Awareness: Workers can quickly identify dangers and
navigate the facility safely.
o Efficient Workflow: Reduces wasted time searching for locations or materials.
o Faster Emergency Response: Clear pathways and signage enable quicker
evacuation and emergency personnel access.

III. Adequate Rest Areas with Ergonomic Seating for Breaks:

 The Challenge: Working in a factory, especially with repetitive tasks or demanding

physical labor, can be physically and mentally taxing. Without proper breaks and rest,
fatigue accumulates, leading to decreased performance and increased accident risk.
 Implementation Strategies in Layout:
o Designated Break Rooms: Provide sufficient space for all shifts, separate from
the production floor to offer a true respite.
o Ergonomic Seating: Equip break rooms with comfortable, supportive chairs and
tables. Avoid uncomfortable hard plastic or metal seating. Consider chairs with
back support and adequate padding.
o Amenities: Offer clean restrooms, access to drinking water, and facilities for
eating meals (e.g., microwaves, refrigerators).
o Quiet Environment: Ensure break areas are reasonably quiet, away from high-
noise production zones, allowing workers to truly rest and de-stress.
o Accessibility: Ensure rest areas are easily accessible from all parts of the
production floor, promoting their use.
 Ergonomic and Safety Benefit:
o Fatigue Reduction: Allows workers to physically and mentally recover, reducing
the risk of errors and accidents during subsequent work periods.
o Improved Morale and Job Satisfaction: Shows that the company values
employee well-being, leading to higher retention rates.
o Enhanced Productivity: Well-rested workers are more alert, focused, and
productive.
 o Health Benefits: Encourages proper hydration and nutrition, which are crucial for
maintaining energy levels.

Ergonomic Factors Considered: Accessibility

Wide Aisles (at least 1.2 meters) for Easy Movement of Workers and Equipment:

 The Challenge: Beverage factories involve a mix of pedestrian traffic, movement of

materials (often using forklifts or AGVs), and the potential for spills. Narrow aisles
create hazards and bottlenecks.
 Implementation Strategies in Layout:
o Minimum Width: Design aisles to be at least 1.2 meters (approximately 4 feet)
wide. This is a general guideline, but wider aisles are preferable in areas with
heavy forklift traffic or where workers frequently carry bulky items.
o Dedicated Traffic Lanes: Clearly mark separate lanes for pedestrian traffic and
forklift/AGV movement. Use floor markings and signage to enforce these lanes.
o Clearance Around Machinery: Ensure sufficient space around machinery for
operation, maintenance, and cleaning.
o Emergency Exits: Aisles leading to emergency exits must be wide and
unobstructed.
o Turning Radii: Consider the turning radius of forklifts and other equipment
when designing aisle intersections and corners.
 Ergonomic and Safety Benefit:
o Reduces Collisions: Minimizes the risk of collisions between workers,
equipment, and stationary objects.
o Improves Efficiency: Allows for smoother movement of materials and personnel,
reducing travel time and bottlenecks.
o Enhances Safety: Provides ample space for workers to react to unexpected
events (e.g., a spill or a malfunctioning machine).
o Facilitates Evacuation: Wide, clear aisles are crucial for safe and rapid
evacuation in case of an emergency.
II. Non-Slip Flooring to Prevent Slips and Falls, Especially in Areas Prone to Spills:

 The Challenge: Beverage production often involves liquids, creating a high risk of spills
and slippery surfaces. Slips and falls are a leading cause of workplace injuries.
 Implementation Strategies in Layout:
o Flooring Material: Use flooring materials with a high coefficient of friction (the
measure of how much resistance the flooring offers to slipping). Consider
materials like:
 Epoxy Coatings with Aggregate: Durable and provides excellent slip
resistance.
 Rubber Flooring: Offers good cushioning and slip resistance.
 Quarry Tile: Often used in food processing areas due to its durability and
resistance to chemicals and water.
o Drainage: Ensure floors are sloped slightly towards drains to prevent liquid
accumulation.
o Regular Cleaning: Implement a rigorous cleaning schedule to remove spills
promptly.
o Matting: Use non-slip mats in areas particularly prone to spills (e.g., near filling
machines, washing stations).
o Signage: Use "Caution: Wet Floor" signs when necessary.
 Ergonomic and Safety Benefit:
o Reduces Slips and Falls: Significantly lowers the risk of injuries from slips and
falls, which can range from minor bruises to serious fractures.
o Improves Stability: Provides workers with a more secure footing, reducing
fatigue and improving balance.
o Enhances Confidence: Workers feel more secure and confident in their
movements, leading to increased productivity.