Starting a factory from scratch is one of the most capital-intensive decisions a manufacturer will ever make. Every square meter misplaced, every workflow bottleneck baked into concrete, every utility line run the wrong direction — these are mistakes that compound for decades. iFactory's Greenfield Factory Layout & Engineering Advisory exists to eliminate those costly errors before a single foundation is poured. From production line configuration to utilities infrastructure, we bring data-driven precision to decisions that used to rely on gut instinct. Book a free consultation and let's plan your high-performance facility together.
Build Your Factory
Right. The First Time.
End-to-end engineering advisory for greenfield manufacturing plants — from layout strategy to infrastructure planning.
in Material Flow
Ramp-Up
Through Planning
Why Greenfield Planning Is Different
Unlike retrofitting an existing plant, greenfield development offers a blank canvas — and that's precisely what makes it so risky without expert guidance.
of new factory projects experience layout-related production bottlenecks within their first year of operation
average cost overrun when greenfield infrastructure is planned without a structured engineering advisory process
of manufacturers report that poor initial layout decisions required costly modifications within 3 years of commissioning
6 Pillars of Greenfield Excellence
A structured, end-to-end advisory covering every dimension of your new facility's success.
Production Line Configuration Strategy
We design your production lines around actual output targets, product variants, and cycle time requirements — not industry templates. Using digital simulation, we model throughput, identify choke points, and configure line sequences that match your ramp-up schedule.
Machine Placement & Workflow Advisory
Where a machine sits determines how far every part, person, and tool travels every day. Our advisors use spatial analysis and ergonomics data to place equipment for minimum motion waste, safe operator access, and future maintenance corridors.
Material Flow Optimization Framework
Raw materials, WIP, and finished goods must move with purpose. We map every material journey — inbound receiving, staging, line-feed, inter-process transfer, and outbound — to eliminate cross-traffic and enable lean replenishment.
Warehouse & Dispatch Planning
We advise on rack density vs. accessibility trade-offs, dock door allocation by shift volume, FIFO/LIFO zoning, cold chain requirements, and cross-docking opportunities to make your facility a logistics stronghold from Day 1.
Safety Zoning & Compliance Advisory
Compliance failures discovered post-construction cost ten times more to fix. We embed OSHA, ISO 45001, and local regulatory requirements directly into zone planning — egress, fire suppression, hazmat segregation, and PPE zones are designed in from the start.
Utilities & Infrastructure Planning
Power, compressed air, water, gas, data networks, HVAC, and waste management — all planned around real production demands. We develop load profiles for each zone, size utility runs for future expansion, and eliminate single-point-of-failure risks.
Not sure which pillar matters most for your facility?
Schedule AssessmentFrom Blank Land to Operational Masterpiece
Our advisory follows a proven 5-stage model that turns your ambition into executable engineering reality.
Discovery & Requirements Capture
Deep-dive sessions with your operations, finance, and engineering teams. We extract product range, volume targets, workforce size, compliance obligations, and growth plans for Year 1–5.
Layout Concept & Flow Simulation
We develop 2–3 layout concepts using digital simulation tools. Each concept is stress-tested for peak throughput, shift changeover, emergency scenarios, and expansion pathways.
Detailed Advisory & Zoning
The selected layout is developed into zone-level detail: machine placement, material flow routes, safety zones, utility corridors, and infrastructure sizing — all compliant with applicable regulations.
Engineering Validation & Review
We facilitate structured review with your construction team, equipment vendors, and compliance officers. All conflicts are resolved before design freeze — saving costly construction change orders.
Implementation Support & Handover
We stay engaged through construction milestones, equipment installation, and commissioning. Advisory continues into ramp-up, ensuring the facility performs as planned — not just as built.
Don't Design Your Factory on Assumptions
In 30 minutes, our greenfield experts will identify the 3 biggest layout risks in your current plans — and show you exactly how to eliminate them before construction begins.
What Good Planning Actually Looks Like
The visible difference between a factory designed by experience versus one designed by spreadsheets.
Without Advisory
- Random machine placement by vendor preference
- Material crossing multiple zones repeatedly
- Safety compliance added as an afterthought
- Utilities undersized for full production load
- Dispatch congestion during peak shifts
With iFactory Advisory
- Lines configured for minimum cycle time
- Material follows single, unidirectional flow path
- Safety zones embedded from Day 1 of design
- Utilities sized for peak load + 20% headroom
- Dedicated dispatch corridors for peak efficiency
Engineering Intelligence Meets Manufacturing Reality
Our advisors have lived inside factories, not just consulted from outside them.
Digital-First Advisory
Every recommendation is backed by simulation data, digital twin scenarios, and 3D modeling that validate decisions before concrete is poured.
Multi-Sector Expertise
Automotive, electronics, food & beverage, pharma, aerospace — our team brings cross-sector knowledge that prevents siloed thinking in plant design.
ROI-Driven Decisions
Every layout recommendation is evaluated through a financial lens. We quantify cost impact so your stakeholders see clear value in every decision.
Compliance Built-In
Regulatory requirements are a first-pass design constraint — not a final-phase checkbox — saving you from expensive redesigns and audit failures.
Scalability Built-In
We plan for your Day 1 AND your Year 5. Future production zones, automation pathways, and footprint expansions are modeled into the original layout.
Collaborative Approach
We integrate seamlessly with your architects, civil engineers, and equipment vendors — acting as the orchestrating intelligence that keeps all parties aligned.
Who Benefits Most From This Advisory
Greenfield advisory delivers maximum value at these critical moments in your manufacturing journey.
New Manufacturing Ventures
You've secured land and funding. Now you need an engineering blueprint that maximises investment from Day 1 — not a layout that leaves expensive redesigns for Year 2.
Global Expansion Projects
Opening a new facility in an emerging market? Local regulations and logistics infrastructure require a fresh-eyes approach — not a copy-paste of your existing plant.
Automation-Ready Facilities
Designing with AGVs or cobots requires infrastructure pre-planning that traditional contractors miss. We design for the automation you're installing in Year 3.
High-SKU Complex Producers
If you manufacture 50+ product variants across multiple lines, your material flow complexity multiplies exponentially. Advisory is the difference between chaos and control.
Common Questions About Greenfield Advisory
Everything you need to know before booking your session.
When in the project lifecycle should we engage iFactory advisory?
The earlier, the better — ideally at the feasibility or site-selection stage. However, we regularly engage during schematic design or early detailed design with significant benefit. Advisory after construction begins still delivers value but carries diminishing returns as structural decisions become locked.
What's the difference between your advisory and a standard architecture firm?
Architects design compliant, beautiful buildings. We design manufacturing systems inside those buildings. Our expertise is production flow, machine ergonomics, material handling, and operational efficiency. We work alongside your architects, not instead of them.
How do you handle facilities in highly regulated industries?
Pharmaceutical, food safety, and defense facilities require compliance baked into layout — cleanroom airflow, contamination zones, access control. Our team includes advisors with direct experience in FDA, FSMA, ITAR, and AS9100 compliant facility design.
Can iFactory advise on a phased build approach?
Absolutely. We routinely design phased facility strategies where Phase 1 operates at 40–60% capacity with Phase 2 and 3 pre-planned in layout, utilities, and infrastructure. This avoids costly disruption of expanding a facility not designed to grow.
Do you provide documentation for construction teams and vendors?
Yes. Deliverables include zone layout drawings, machine placement guides, material flow diagrams, utility load schedules, compliance checklists, and an operational readiness brief — in formats usable by construction, procurement, and operations teams.
How long does the full advisory engagement take?
A standard greenfield advisory runs 10–14 weeks from discovery to validated design freeze. For larger facilities above 50,000 sqm we recommend 16–20 weeks. Book a free session to get a timeline scoped to your specific project.
Your Factory's Future Is Decided in the Planning Room
Don't leave the most consequential engineering decisions to chance. Let iFactory's advisory team turn your greenfield vision into an operational advantage that pays for itself many times over.
