Plant setup & EPC
Turnkey manufacturing plant setup — greenfield and brownfield
From an empty shed or a bare plot to a plant that produces to plan. Mecwerx engineers the layout, builds the production equipment, coordinates utilities, installs, commissions and stays until output is stable — one contract, one point of accountability.
At a glance
- Scope
- Layout, process, utilities, equipment, lines, installation, commissioning
- Project types
- Greenfield, brownfield expansion, line addition, relocation
- Buyers
- OEMs, Tier-1/2 suppliers, SMEs scaling up, new entrants
- Timeline
- Indicative 4–12 months, depending on scope
- Handover
- Drawings, BOMs, SOPs, FAT/SAT records, training
Overview
One contract from layout to stable production
Most plant projects in India are executed as a chain of separate contracts — a layout consultant, a civil contractor, a machine builder, a conveyor vendor, an electrical contractor and an automation integrator. Each delivers its piece to its own drawing. When the line does not reach rated output, every vendor can prove their piece works. The gap between them is where time, money and start-of-production dates are lost.
Mecwerx takes responsibility for the whole production system. We start from your product, volumes and target cost, and work backwards into the process, the layout, the equipment list and the utilities load. We then engineer and build the production equipment, manage installation on your site and commission the plant against agreed output and quality criteria.
You deal with one project manager, sign off stage gates, and receive one set of documentation at handover. Civil and building works can be included in our scope or coordinated with your contractor using our layout and load data — whichever gives you better control.
What we build
What a turnkey plant scope covers
Plant master layout
Block layout, material flow, column-grid checks, expansion zones, aisles and safety walkways — frozen before money is spent on steel.
Process design & line balancing
Process sequence, cycle times, takt, manpower and station count derived from your volumes and product mix.
Equipment specification & build
SPMs, fixtures, assembly lines, conveyors, workstations and test equipment designed and built to the frozen process.
Utilities engineering
Power load schedule, compressed air, cooling water, lighting, ventilation and fume extraction sized to the equipment list.
Material handling & storage
Receiving, stores, kitting, line-side supermarkets, WIP and dispatch — sized and designed as part of the flow.
Electrical, controls & integration
Panels, PLC/HMI, safety circuits, andon and data capture so the plant runs as one system.
Installation & commissioning
Foundation and anchoring data, erection, alignment, dry runs, trials, FAT/SAT and ramp-up support.
Brownfield expansion & relocation
New lines inside running plants, shutdown-window installations and relocation with minimum loss of output.
Documentation & training
As-built drawings, BOMs, SOPs, maintenance schedules and operator training aligned to real shop-floor work.
Technical
Turnkey Plant Setup — applications, specifications and deliverables
The same three-part technical structure on every solution page, so engineering and procurement can compare scopes without reading marketing copy.
Applications
What it is applied to
- New plants for automotive and EV component programmes
- Capacity expansion for a new customer or model
- Localising imported sub-assemblies
- Consolidating two sites into one
- Moving from manual to semi-automated production
- Setting up close to an OEM for just-in-time supply
Not listed? Describe the operation — most scopes we quote are variations on these.
Typical specifications
What we engineer to
- Scope boundary
- Greenfield or brownfield — building interface to finished-goods despatch
- Plant capacity
- Designed to your target output per shift, with a stated expansion step
- Shift pattern
- 1, 2 or 3 shifts — drives equipment count, buffers and manpower
- Line count
- Single line to multi-line plant, phased by capital release
- Automation level
- Manual, semi-automatic or automated, chosen per station on payback
- Utilities engineered
- Power distribution, compressed air, water, exhaust, earthing
- Controls architecture
- Standalone machines, line PLC, or line PLC with plant-level data
- Safety architecture
- Risk assessment per ISO 12100; guarding, interlocks and e-stop zones
- Traceability
- Optional per-part logging and MES/ERP interface
- Indicative timeline
- 16–40 weeks from design freeze, phased by area
Indicative ranges. Final specifications are fixed against your part and volume at design freeze.
Engineering deliverables
Documents you receive
- Plant and equipment layout drawings (current, proposed and phased)
- Process flow, capacity model and manpower plan
- Equipment schedule with specifications and utility loads
- Utility single-line diagrams and service routing drawings
- Machine and line GA drawings, 3D models and BOMs
- Electrical schematics, panel drawings and I/O lists
- PLC, HMI and robot program backups
- FAT and SAT protocols, commissioning records and punch-list closure
- Operation and maintenance manuals, SOPs and spares lists
Programs and drawings are handed over, so your team is never dependent on us for a change.
Engineering scope
How each element is engineered
The design decisions behind the specification above.
| Project types | Greenfield plants, brownfield expansions, line additions, plant relocation and consolidation |
|---|---|
| Plant size | Scoped per project — from a single assembly bay to multi-line facilities |
| Processes | Assembly, welding and fabrication, testing, packing and intralogistics, with machining support |
| Layout deliverables | 2D block and detailed layouts (AutoCAD), 3D models of equipment, flow studies where needed |
| Utilities data | Connected-load schedule, compressed-air demand, cooling, lighting and ventilation data for your civil/MEP contractor |
| Controls platforms | Siemens, Mitsubishi, Allen-Bradley, Delta, Omron — or your plant standard |
| Safety | Machine risk assessment on ISO 12100 principles; guarding, interlocks and safety circuits |
| Commercial models | Lump-sum turnkey, design & build, or phased (engineering study first, then build) |
Handover
What you receive
Every plant setup project closes with a documented handover — not just a machine on the floor.
- Frozen plant layout and material-flow drawings
- Process sheets, cycle-time and line-balance study
- Equipment GA drawings, BOMs and spare-parts lists
- Electrical drawings, PLC program backups and I/O lists
- FAT and SAT protocols with signed results
- Operator and maintenance SOPs with training records
- As-built documentation and a post-handover support plan
Execution
How we execute a turnkey plant project
One project manager, stage gates you sign off, and no hand-offs between vendors.
Study
Site visit, product and volume review, constraints, budget envelope and risk list.
→ Scope note + indicative budget
Engineer
Process design, layout options, equipment specifications and utilities data. You freeze the layout.
→ Design freeze
Build
Manufacture of equipment, fixtures and lines with stage inspections.
→ Factory acceptance test (FAT)
Install
Erection, alignment, utilities hook-up and safety checks on your site.
→ Mechanical & electrical completion
Commission
Dry runs, trial production, capability and cycle-time proving.
→ Site acceptance test (SAT)
Stabilise & support
Ramp-up support, operator training, punch-list closure and handover.
→ Handover dossier + support plan
Applications
Where it is used
- New plants for automotive and EV component programmes
- Capacity expansion for a new customer or model
- Localising imported sub-assemblies
- Consolidating two sites into one
- Moving from manual to semi-automated production
- Setting up close to an OEM for just-in-time supply
Industries we serve
Why Mecwerx
Why manufacturers choose us for this
Single-point accountability
One contract, one project manager and one set of acceptance criteria. If output is not met, exactly one party is responsible for fixing it.
Engineering before steel
Layouts, cycle times and utilities are frozen on paper first. The most expensive plant mistakes are layout mistakes discovered after installation.
Output-based acceptance
We commission against agreed cycle time, quality and uptime criteria — not just 'the machine runs'.
Documentation you can run on
Drawings, programs and SOPs are handed over, so your team can operate and maintain the plant without depending on us.
Quotation checklist
What we need for an accurate plant setup quote
Send what you have. Missing details are fine — we will fill the gaps during the technical discussion.
- Product drawings or samples, and the variant list
- Annual volume, shifts per day and target cycle time
- Plot or building layout (DWG/PDF) with column grid and height
- Available power and compressed-air capacity
- Current process (if brownfield) and main pain points
- Target start-of-production date
- Quality requirements from your customer
- Budget envelope, if already defined
FAQ
Turnkey Plant Setup: common questions
What does turnkey plant setup include at Mecwerx?
Everything needed for the plant to produce: process design, layout, utilities data, production equipment (lines, SPMs, fixtures, conveyors, workstations), electrical and controls integration, installation, commissioning, training and documentation. Civil and building works can be included or coordinated with your contractor.
How long does a turnkey plant project take?
It depends on scope. A single assembly line inside an existing building is often 3–6 months from design freeze; a complete greenfield plant typically runs 6–12 months including civil works. You get a stage-wise schedule after the study phase.
Do you handle brownfield expansion in a running plant?
Yes. Equipment is pre-built and tested before it reaches site, and installation is sequenced into weekends, shutdowns or phased cut-overs to protect current output.
Can you work with our existing civil or MEP contractor?
Yes. We supply layout, foundation and load data, the utilities schedule and interface details, and coordinate the contractor so the building is ready when the equipment arrives.
How is a turnkey project priced?
Most turnkey projects are quoted lump-sum against a frozen scope, with milestone payments linked to design freeze, FAT, delivery, installation and SAT. For early-stage projects the engineering study can be quoted separately first.
Where do you execute plant projects?
We are based in Greater Noida (NCR) and execute across India — including Noida, Gurugram-Manesar, Faridabad, Bawal-Neemrana, Pune, Chennai and other industrial clusters.
Related
Related solutions
Assembly Lines
Takt-balanced manual, semi-automatic and automated lines with conveyors, error-proofing and traceability.
Learn morePlant Layout & Process Optimisation
Measured layout, line-balancing and lean studies — implemented on your floor, with before/after results.
Learn moreInstallation & Commissioning
Installation, commissioning, plant shifting and ramp-up support — accepted against written criteria.
Learn moreStart a project
Hand over your production challenge.
Tell us what the line has to produce, where, and by when. We will come back with a scoped approach, a realistic timeline and the questions that matter — usually after a site visit or a drawing review.
- +91 85959 55435 · Mon–Sat, 09:00–18:00
- WhatsApp an engineer
- info@mecwerx.com
- Detailed RFQ with drawings (PDF, DWG, STEP)