The most costly factory mistakes do not show on the drawings but in daily operation: forklifts covering long distances back and forth, raw materials passing through the finished-product area, workers moving between the ends of the hall, and expansion made impossible because the line is boxed in by walls. These mistakes cost time, energy and quality every day for years. The solution is designing the factory around the production flow: the architect starts from the production line, not the building's shape. This guide explains the basic stages of flow, common layouts, what is designed around the line, designing for expansion, and common mistakes.
The Basic Stages of Flow
- Receiving raw materials.
- Initial storage.
- Manufacturing or assembly.
- Inspection and quality.
- Packing and packaging.
- Finished goods storage.
- Shipping.
The principle: one-way flow as far as possible, with the shortest distances, and no crossing between raw and finished. This principle is decisive in food factories. Read: Food factory requirements.
Common Layouts
| Layout | Suits | Note |
|---|---|---|
| Straight (I) | Entrances and exits on opposite sides | The simplest flow; needs a long plot |
| U-shape | Receiving and shipping on the same side | Groups the docks and saves on roads |
| L-shape | Plots with particular dimensions | Flexibility on irregular plots |
The choice of layout is tied to the position of entrances and internal roads. Read: Factory internal roads and Loading dock design.
What Is Designed Around the Line
- Services: electricity, compressed air, water and drainage at each machine. See our electrical load calculation service.
- Floors: according to equipment loads and vibration.
- Overhead cranes and their effect on the structure. Read: Steel or concrete hangars.
- Safety: escape routes and the fire system around the line. Read: Civil defense requirements for factories.
- Energy efficiency: within the requirements of MODON's guides for factories.
The Information the Designer Needs From You
| Information | Why |
|---|---|
| Equipment list with dimensions and weights | Sets the hall, floors and structure |
| Electrical loads and services for each machine | Sets transformers and services |
| Raw materials, products and quantities | Sets stores and hazard classification |
| Number of workers and shifts | Sets facilities, parking and exits |
| Expected expansion plan | Sets the reserved areas |
Design for Expansion
Leave a logical extension for the line, and an electrical base that can take the increase. Read: Expanding an existing factory.
Common Mistakes
- Designing the building first and then fitting the line into it.
- The raw material route crossing the finished product.
- Stores far from the points of use.
- Columns in the path of the line or cranes.
- Leaving no space to extend the line.
Frequently Asked Questions
When should I decide the equipment?
Before design; it determines dimensions, loads and services.
Does the flow affect licensing?
Indirectly; it determines the design that gets approved and the safety drawing linked to it. Read: Industrial building permit documents.
What if the production line changes later?
Read: Production line changes and licences.
Do I need a production consultant alongside the designer?
In complex factories, coordinating the equipment supplier with the engineering designer from the start helps.
Does a steel design suit every factory?
It suits most for wide spans; the final decision depends on activity and loads.
How Abak Engineering Consultancy Helps
Abak is an accredited engineering office that designs factories starting from the production line: one-way flow, services at each machine, a structure suited to cranes, space for expansion, and safety drawings. See our factories and warehouses design service, or contact us.
Regulatory information is based on the Balady platform and the Ministry of Municipalities and Housing, and procedures may be updated by the competent authority. Last reviewed: October 2026.