Technological design · food industry

We develop technology for food plants

We do not design buildings. We develop technology and technological solutions for food plants, catering operations, food warehouses and related production facilities — compliant with HACCP, ISO 22000, IFS and BRCGS requirements and Lean principles. We have worked for investors in the USA, the United Kingdom and Europe.

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Company

GILTEH

Industry

Technology and technological solutions

Experience

15+years in food technology

Facilities

100+facilities with our technology

Markets

USA · United Kingdom · European Union

Requirements

HACCP · ISO 22000 · IFS · BRCGS

Method

Lean — flow without waste

Tools

3D / BIM model — Autodesk Revit

Who we work for

Every type of plant needs a different approach

Each group of businesses has its own organisation and way of working. Besides specific requirements, there are hygiene requirements common to all — without them no food plant can maintain a high standard of sanitary culture.

Food industry

Meat, fish, dairy, fruit and vegetable processing plants, bakeries, production of frozen foods and semi-finished products.

Catering

Restaurants, central kitchens, canteens, catering, hotels with catering facilities.

Retail and warehousing

Shops, distribution centres, cold and freezer stores, food logistics warehouses.

Other production plants

Industrial facilities related to the food sector: production of packaging, feed, chemicals and more.

Offer · Engineering

Production process engineering

Technological engineering is a comprehensive process covering the analysis, development, verification and implementation of technological processes, equipment and production systems. We combine the knowledge of a technologist, a process engineer and a food safety specialist so that the plant works efficiently, safely and in line with customer requirements from day one.

We are not a building design office. We develop the technology: what will be produced, how and on which equipment. Based on our technological solutions, the architect and trade designers prepare the building design.

We develop every technological solution in accordance with the requirements of:

HACCPhazard analysis and critical control points
ISO 22000food safety management
IFS Foodretail chain standard
BRCGSglobal food safety standard
Leanvalue flow without waste

Process analysis

We examine existing or planned production processes: material flow, operation times, bottlenecks, downtime and energy consumption. The goal is maximum efficiency, minimum waste and stable product quality.

Development of technological processes

We develop a detailed course of every production stage — from raw material preparation to final processing and packaging — and select the processing methods suited to the given product.

Equipment selection

We select machines and lines that meet process requirements, taking into account capacity, accuracy, cost, durability and hygienic design.

Modelling and simulation

In a 3D model and simulation tools we check the layout and sequence of operations before anything is built. Assessing the effect of parameters on the product reduces the risk of costly changes on site.

Technological cards

We prepare documentation describing each step of the process: parameters, quality requirements and control points. It ensures repeatable production and makes staff training easier.

Optimisation and innovation

We look for new technologies, materials and working methods that reduce costs, improve product quality or increase efficiency.

Sustainability

We reduce the environmental impact of production: less waste, economical use of water and energy, environmentally friendly materials and technologies.

Occupational safety

We develop processes in accordance with health and safety regulations to minimise risk to personnel and equipment.

Well-developed technology is the foundation of a successful production investment: the product is made at the highest possible quality, on time and at optimal cost.

Technological solution

Technological documentation

What a technological solution includes

Technology is the most demanding stage of preparing a food investment: it determines how the plant will produce, how much it will cost and whether it will meet customer requirements. Our solution takes into account all aspects of the technological process, food law and food safety standards, health and safety regulations and the profitability of production.

Production area and layout of technological lines
Production-related rooms: raw material and product stores, cold rooms, freezer rooms, packing rooms
Administrative, utility and staff welfare and sanitary rooms
Engineering facilities: boiler rooms, transformer stations, generators
Equipment list and utilities balance as input data for the trade designers
3D model of the plant in Autodesk Revit

We develop hygiene zones, one-way flows of raw material, product, personnel and waste, and the layout of rooms so that the plant is ready for IFS, BRCGS or ISO 22000 certification and official inspections.

Technological concept

Layout of rooms and lines, capacity, areas and preliminary equipment selection. It allows you to assess the investment before full documentation is prepared.

Technological documentation

Drawings, description of the technology, equipment list and data for the architect and trades: structure, ventilation, refrigeration, installations.

Modernisation and extension

Analysis of the existing plant, removal of crossing flows, new lines and increased capacity.

3D / BIM model

Visualisation of the plant in Revit: easier investor decisions and fewer clashes between trades on site.

Efficiency · Savings · Flexibility

We develop technology in line with Lean principles

Lean manufacturing in production technology is an approach that ensures maximum efficiency, low costs and process flexibility already at the stage of technology development, not only after the facility is built.

The traditional approach often focuses only on the placement of equipment. The Lean approach focuses on a continuous flow of value: from receiving raw material to dispatching the finished product.

GILTEH — we develop today. We build an efficient tomorrow.

Flow diagramone-way

Raw material receivinginspection and unloading
Raw material storecold / freezer room
Productionline with no backflow
Packingclean zone
Dispatchshipping of finished product

Process without waste

No unnecessary movement, storage or transport.

Cost optimisation

Fewer unnecessary square metres, machines and labour.

Functional space

Every metre has its task in the process.

Sustainability

A plant ready for new products and expansion.

Selected projects

Plants with our technological solutions

Fish and meat processing, food production, logistics and cold stores. Click to enlarge the visualisation.

International experience

Solutions for the most demanding markets

GILTEH technological solutions have been developed for facilities in the United States, the United Kingdom and European Union countries. We know different regulatory systems and customer standards, so the solution matches the requirements of the market the product will go to from the start.

USChicagoUnited States
USPhiladelphiaUnited States
UKUnited KingdomGreat Britain
EUEuropean UnionEU member states
100+facilities delivered in Ukraine — experience we are now bringing to the Polish market

How we work · From idea to finished technology

From the first conversation to complete technological documentation

Brief and analysis

We learn your needs: product range, capacity, building or site, budget and customer requirements. We propose a solution.

Technological concept

Layout of rooms and lines, flows of raw material, personnel and waste, preliminary equipment selection.

Technology development

Drawings, description of the technology, equipment list and 3D model compliant with HACCP, ISO 22000, IFS, BRCGS and Lean principles.

Handover of documentation

A full set of drawings and input data for the architect and trade designers. We answer their questions about the technology.

About

A technologist who knows the plant from the inside

The GILTEH team combines extensive experience in developing technology for food and production plants, food safety and production organisation.

As a result, the technological solution takes hygiene requirements, flows and the real work of staff into account from the start, not just the placement of equipment. We do not only understand the potential of new ideas; we put them into practice so that they deliver results in both the short and the long term.

Ivan Giletskyi

Chief Technologist

Engineer-technologist with over 15 years of experience. A food safety expert who brings this knowledge into technological solutions for plants.

Ivan Giletskyi on a construction site, at the drawing board and in a production plant

15+years of experience in food plant technology

40+brands among our clients

100+facilities with our technology

3foreign markets: USA, United Kingdom, European Union

3Dplant model in Revit before construction starts

Clients

They trust us

Frequently asked questions

Before you call

Do you have experience outside Ukraine and Poland?

Yes. We have developed technological solutions for facilities in the USA (Chicago, Philadelphia), the United Kingdom and European Union countries. In Ukraine we have delivered more than 100 facilities.

Do you work for plants in Poland?

Yes. We develop technological solutions in line with EU food law and take into account the requirements checked by the official control authorities in Poland — the State Sanitary Inspectorate and the Veterinary Inspectorate.

Does GILTEH design buildings?

No. We develop the technology and technological solutions: what will be produced and how, the layout of lines and rooms, flows, equipment and hygiene conditions. Based on these, the architect and trade designers (structure, ventilation, refrigeration, installations) prepare the building design.

Do the solutions meet HACCP, ISO 22000, IFS and BRCGS requirements?

Yes. We develop technological solutions in line with these standards: we separate hygiene zones, eliminate crossing flows of raw material, finished product, personnel and waste, and choose materials and equipment of hygienic design. As a result the plant is prepared for certification and retail chain audits.

What does the Lean approach mean?

We develop a continuous, one-way flow of value: no unnecessary transport, storage or movement. The result is a smaller footprint, less non-value-adding work and lower operating costs.

Do you develop technology modernisation for an existing plant?

Yes. We analyse the current layout and propose changes that increase capacity and remove flow problems, taking into account the operation of the plant during the rebuild.

What is a technological design of a food plant?

A technological design defines how the plant will work: which production processes take place in it, how rooms and lines will be arranged, how raw material, product, personnel and waste move through it and what equipment is needed. It is the basis for the architect and trade designers and for obtaining approvals and certificates.

What plants do you develop technological solutions for?

For meat, fish, dairy, fruit and vegetable processing plants, bakeries and confectioneries, production of frozen foods and semi-finished products, central kitchens, catering and restaurants, as well as cold and freezer stores and food distribution centres.

Do you help prepare a plant for IFS, BRCGS or ISO 22000 certification?

Yes, as regards technology and plant layout. We design hygiene zones and flows so that the plant meets HACCP, IFS Food, BRCGS and ISO 22000 requirements. We do not carry out audits or quality system consulting.

How do I request a quote for a technological design?

Call or write to the manager: Maksym Giletskyi, tel. +48 452 868 802, gilteh.pl@gmail.com, or fill in the form on this page. Give us the product range, planned capacity, location or building plan and deadline. We prepare a quote after a short conversation.

What should I prepare for a quote?

A short description is enough: product range and planned capacity, location or plan of the existing building, deadline. After a conversation we will prepare the scope of work and an offer.

Contact

Tell us about your plant

Write a few words about your investment. We will reply and propose a time for a call.

Client Manager Maksym Giletskyi First contact, quotes and organising cooperation +48 452 868 802 gilteh.pl@gmail.com