Precision in Practice: MRWAPL’s 45-Metre Engineering Feat

One of the earliest proponents and adopters of PEBs, MRWAPL completes a challenging premixes plant project within 12 months.

M.R. Warerkar and Associates’ (MRWAPL) project for Trouw Nutrition involved building a state-of-the-art premixes plant for animal feed in Jadcherla, Telangana. Built on a 3.5 acre plot, the 5,000 sq.mt factory comprised several structures, including a 45-metre-tall tower. The project was completed within 12 months, despite the challenges of building a 9-storeyed 45-metre-tall tower and other structures of various heights, and integrating them into a PEB factory.

The 45m high tower had to be designed as per the prevailing wind loads, earthquake loads, and specific equipment loads. To achieve this, star columns were used which were then enclosed in panels to prevent them from collecting any dust - a critical requirement considering the necessary hygiene and good manufacturing practices.


Portal bracings were provided at strategic locations to achieve the desired stability of the structure, without affecting the equipment layout or movement within the factory. The total tonnage of the building was about 750 tons. With wind load being an extremely vital factor at that height, due care had to be taken to ensure that all the design parameters were accounted for.

Several design workshops were held between MRWAPL, the client, and the PEB supplier to ensure the design was sturdy and economical, all of which met the requirements for processing, firefighting, and for placing various machines, piping, cut-outs etc.

The equipment was supplied by a reputed MNC. It consisted of gravity flow of material top to down, which required very specific floor wise detailing of supports and cut-outs for the various equipment, leaving no margin for error. This was very well planned and was achieved at site without having to do any rework.

The erection of the high tower was another challenge, considering the limited space, and involvement of other agencies. The tower was clad with rockwool panels from the outside for its aesthetics, firefighting, and comfort requirements.

MRWAPL, started by M.R. Warerkar and S.B. Shah, is now presided over by the next generation of the family, Parag Warerkar and Manish Shah. Leading a highly trained technical team of over a hundred, they have blazed the way for industrial design by means of a simple design philosophy: SWIFT, an acronym that stands for Sustainable, Worker-Friendly, Industry-Leading, Finessed, and Time-Bound delivery. MRWAPL has designed over 2000 factories for companies like PepsiCo, Varun Beverages, Britannia, Maruti Suzuki, Supreme, and Relaxo, to name a few.