What We Did

• Pre-Investment and Strategic Advisory:

  IMARC conducted comprehensive feasibility analysis covering raw material sourcing (molasses from Brazil and Thailand), utility costs, and competitive positioning against imports. Our location analysis evaluated KIZAD, Jebel Ali and Ruwais, considering factors including proximity to Khalifa Port, availability of industrial steam, effluent treatment infrastructure, and free zone incentives. We prepared detailed CapEx estimates of AED 180 million and 15-year financial projections achieving 22% IRR. Our regulatory team navigated UAE's Federal Authority for Nuclear Regulation requirements for sterilization equipment, Abu Dhabi Department of Economic Development licensing, and Emirates Authority for Standardization and Metrology (ESMA) product certification pathways. We facilitated halal certification pre-approval from the Emirates International Accreditation Centre.

• Engineering & Design Services:

  Our engineering team designed a state-of-the-art fermentation facility featuring 12 stainless steel fermenters (200 KL capacity each) with automated CIP systems. We developed utilities planning for 850 KW power demand, 180 m³/hour process water with triple-stage RO system achieving 75% water recycling, and a 15 TPH steam generation system. The HVAC design incorporated insulated fermentation halls maintaining 28-30°C despite exterior temperatures, with 15 ACH for contamination control. Clean room design for inoculum preparation areas met ISO Class 7 standards. Our waste management system planning included anaerobic digestion for high-COD effluent (18,000 mg/L) and gypsum recovery from neutralization processes, achieving 92% waste valorisation.

• Procurement & Supply Chain Support

  We conducted global supplier evaluation for fermentation equipment, ultimately selecting European manufacturers for fermenters and crystallization systems, and identifying cost-effective Asian suppliers for filtration and drying equipment. Our team managed procurement of specialized Aspergillus niger culture strains from international biotech suppliers and established technical specifications for 316L stainless steel equipment with pharma-grade surface finishes. We identified three potential contract manufacturers in India and China for backup supply during ramp-up phase and created comprehensive bill of materials covering 2,847-line items. Our procurement strategy achieved 16% savings through strategic bundling and negotiated payment terms.

• Project Execution & Site Management:

  IMARC deployed a turnkey project management team for 20 months, coordinating with 23 specialized vendors. We managed civil construction of fermentation halls with epoxy-coated floors, sterile water storage tanks, product warehousing with temperature control (15-25°C), and administrative facilities. Our multi-vendor coordination ensured integration of fermentation systems, downstream processing (filtration, ion exchange, crystallization), automated packaging lines, and ERP systems. Fire safety implementation included FM-200 gas suppression for electrical rooms, foam systems for chemical storage, and emergency response protocols. We established temporary utilities including desalination units and diesel generators during construction phase.

• Operations Readiness & Ramp-Up:

  Our team developed 52 SOPs covering fermentation protocols, aseptic techniques, quality control procedures, and maintenance schedules. We conducted pilot batches validating fermentation cycles (7-day batch time) and recovery rates (achieving 89% conversion efficiency). Operator training programs covered biochemical principles, sterilization protocols, and troubleshooting of fermentation deviations. We established preventive maintenance schedules for critical equipment including fermenter agitators, centrifuges, and spray dryers. Post-commissioning monitoring tracked key parameters: fermentation efficiency, crystal purity (99.5% minimum), and energy consumption per MT product.

Final Results

The facility achieved successful commissioning in 19 months, ahead of the 20-month schedule. Production ramp-up reached 80% capacity within 3 months, producing food-grade citric acid monohydrate and anhydrous meeting USP/FCC specifications. Final CapEx of AED 174 million delivered 3.3% savings versus budget.

The client secured halal certification and FSSC 22000 certification within first year of operations. Supply agreements with major F&B manufacturers across GCC (including beverage companies, confectionery manufacturers, and pharmaceutical firms) ensured 92% capacity utilization. The facility generates 65% lower carbon footprint compared to imported citric acid when accounting for transportation emissions.

Our water recycling systems achieve 75% recovery, critical in UAE's water-scarce environment, saving AED 2.8 million annually in desalination costs. The project established UAE as a regional citric acid hub with export potential to East African markets.