Davis Brody Bond Architects

Irapuato, Mexico

Completed in 2010 in Irapuato, a city in the south-central region of Mexico's Guanajuato state, Procter & Gamble's (P&G) Planta Milenio illustrates the potential gains of rethinking the architecture of today's factories. While the design, by architects Davis Brody Bond with engineering designer and project manager Arup, is rooted in the company's industrial process, it balances utilitarian goals with those that have emerged in the global economy—environmental sustainability, worker retention, and productivity.

“They wanted as much flexibility as possible,” says Davis Brody Bond partner Christopher K. Grabé. The design team held workshops with P&G employees to understand the manufacturing process. “The idea was to come up with scenarios in which they could move equipment to make the factory more efficient, productive, and ergonomic,” says Grabé.

The team convinced the client that equipment should hang from the ceiling on tracks, while pipes for plastics (the factory makes razors) would run through a walkable underground tunnel, penetrating the floor beneath molding machines. The flexible infrastructure enables reconfiguration, permitting adjustments for future technologies and strategies.

The design also applies moves that until now have been more common in office towers than on factory floors. The architects focused on the issue of daylight, mitigating the harsh Mexican sun with a sawtooth shed roof and skylight system that controls heat gain and withstands the region's torrential rainfalls. Combined with energy-efficient lighting, the strategy gives P&G an average annual savings of $450,000, more than 7 percent of its energy budget. Added to savings from a 100 percent water-reuse plan and other efficient active systems, that number comes to well over $1 million.

Amenities such as a cafeteria, a gym, and athletic fields create collaborative areas where engineers and machine operators can share ideas. Meetings can overlook the production floor for a sense of cohesion in the manufacturing process. “Having a comfortable flow is important,” says Grabé. In a 1.13 million-square-foot facility, a design that fosters direct communication between production, management, and testing labs ultimately saves time and money. The plant is the first of its kind for P&G in Latin America. Given the significant savings, it won't be the last.

Architect: Davis Brody Bond Architects and Planners

Size: 1.13 million square feet

Cost: $100 million

Completion date: 2010

People

Formal name of building:
Planta Milenio (MAPS)

Location:
Irapuato, Guanajuato, Mexico

Completion Date:
2010

Gross square footage:
1.13 million square feet

Total construction cost:
$100 million including $6 million for the land

Owner:
Procter & Gamble

Architect:
Davis Brody Bond Architects and Planners
315 Hudson Street
New York, NY 10013
212.633.4731
212.633.4760

Personnel in architect's firm who should receive special credit:
Davis Brody Bond
Christopher K. Grabé, FAIA, LEED AP, Partner-in-Charge
Oliver Sippl, Project Architect
Beatrix Oetting
Nnadozie Okeke
Matthew Mulkeen
Joao Santos
Takehiko Katayama
Gabriela Hodara
Bruce Dole

Arup
Duncan White, Project Principal
Joshua Yacknowitz, Lead Mechanical Engineer
Julian Astbury, Lead Electrical Engineer
Carlos Valverde, Design Manager

Local architect(s):
Grupo Sagmac
Nueva York #310
Col. Napoles, Mexico, D.F.

Local Design Manager from Sagmac: Juan Sandoval

Interior designer:
Davis Brody Bond

Engineer:
Arup
77 Water Street
New York, NY 10005
955 Massachusetts Avenue
Cambridge, MA 02139

Consultant(s):
Landscape:
Eduardo Lugo
Entorno Arquitectura de Paisaje
24 Sur 4905 Los Pilares
Puebla, Puebla 72560
Mexico

Lighting: Arup

Acoustical: Arup

Photographer(s):
Pa'l Rivera, ArchPhoto

CAD system, project management, or other software used:
Auto Cad

 

Products

Structural system
Steel frame structural system

Doors
Entrances: Juan Carlos de Val.
VAL Y VAL , 52(55) 5394 7722
Fax: 52(55) 5382 1325
e-mail: ventas@valyval.com.mx
Av. Framboyanes L. 19 M.VI Cd. Ind.
B. Pagliai, Veracruz 91697
www.valyval.com.mx/
Cuprum alumni

Metal doors: Guillermo Barragan
guillermobr@intdoor.com.mx
INTERNATIONAL DOORS
Guadalajara Mexico, 3338496655
North American doors

Sliding doors: Guillermo Barragan
guillermobr@intdoor.com.mx
INTERNATIONAL DOORS
Guadalajara Mexico, 3338496655
Stanley

Fire-control doors, security grilles: Guillermo Barragan
Raynor

Hardware
Locksets: Guillermo Barragan
guillermobr@intdoor.com.mx
INTERNATIONAL DOORS
Guadalajara Mexico, 3338496655
Hager

Closers: Guillermo Barragan

Exit devices: Guillermo Barragan
Von-duprin

Pulls: Guillermo Barragan
Hager

Interior finishes
Acoustical ceilings: Nubia Corona
nubiacorona@cogutsa.com
COGUTSA; AV. 5 DE FEBRERO 1716 ZONA INDUSTRIAL BENITO JUÁREZ CP. 76120
USG radar.

Suspension grid: Nubia Corona

Millwork:
Paints and stains: Nubia Corona
Sherwin Williams Metalex

Wall coverings: Nubia Corona
Sherwin Williams Kem tone

Floor and wall tile: Garo
Boulevard D'az Ordaz 1539 Centro 36500 Irapuato, Guanajuato
01 462 627 4200
Porcelanite

Carpet:
Gerardo Sanchez
casa_sanchez@hotmail.com
Casa anchez; Leon Gto
477 7133 464
Shaw. Slate; Bon voyage

Furnishings
Office furniture: by PG

Reception furniture:
IRLO.
Bldv. Campestre #505
col. Jardines del Moral
tel 477 7731222 Leon Gto, Mexico
http://www.irlo.com.mx/irloweb.html
Reception desk.

Fixed seating: by PG
Chairs: by PG
Tables: by PG

Lighting
Interior ambient lighting: Amelia Arredondo
aarredondo@delectric.com.mx
Delectric avenida jacarandas # 1038
fraccionamiento espanita. Irapuato Gto.
T5 cooper lighting corelite series.

Downlights: Amelia Arredondo
T5 cooper lighting ' corelite series.

Task lighting: Amelia Arredondo
T5 cooper lighting ' alura; halo series.

Exterior: Amelia Arredondo
T5 cooper lighting

Dimming System or other lighting controls: Schneider Electric Legrand

Conveyance
Elevators/Escalators: OTIS
Calle 10 No. 145, 2do. Piso
Col. San Pedro de los Pinos
México, DF; CP. 01180
(55) 26363000

Plumbing
David Zaragoza
dzaragoza@cymesa.com
CIMESA; Lerma #2111 ; Col.
Mitras Centro; Monterrey
N.L. CP: 64460; MéXICO
Tel/Fax: +52 (81) 8333-0407
Helvex; Lamosa.

Energy
Energy management or building automation system: Salvador Trejo
Snavarro@sinci.com
SINCI ' Guadalajara, jal.
Miguel de Cervantes Saavedra 382-A
Mexicaltzingo
44180 Guadalajara, Jalisco
01 33 3615 3618

Other unique products that contribute to sustainability:
Alberto Guisa.
alberto@guisa.biz
Construcciones Guisa
Irapuato Guanajuato 36650 Mexico
Tel: (462) 124-6277
Water pond (raining and services water reuse)

Solar tracking skylight system: By PG.
4043 N Ravenswood Ave Ste 219
Chicago, IL 60613-5686

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