CASE STUDIES

Mega Kitchens

Powering Mega Scale Industrial Catering with LOT LPG System and Dry Type Vaporizer ICS Foods Project for Tata Pegatron

Executive Summary

When scale meets precision, energy reliability becomes the foundation of performance.

ICS Foods, a leading institutional catering partner for Tata Pegatron, operates a high-volume kitchen serving approximately 7,000 employees and delivering nearly 12,500 meals daily.

To support this scale, Pune Gas designed and commissioned a complete LPG infrastructure using a LOT LPG System integrated with a Dry Type Vaporizer. The solution created a stable, efficient, and scalable energy backbone, ensuring uninterrupted kitchen operations, enhanced safety, and consistent performance under peak demand conditions.

Key Stats

Daily Meal Output Supported
~ 0 Meals
LPG Consumption Managed
~ 0 Tons/Month
Operational Downtime
0 Fuel Related Interruptions

Operational Scale and System Overview

 

  • Meals served daily: ~12,500 
  • Employees catered: ~7,000 
  • LPG consumption: ~5 to 6 tons per month 
  • System deployed: LOT LPG System with Dry Type Vaporizer 
  • Integrated safety: LeakCheck monitoring system

Client Overview

ICS Foods manages large-scale institutional catering operations where consistency, speed, and reliability are critical. At the Tata Pegatron facility, the kitchen operates across multiple service cycles, requiring uninterrupted fuel supply and precise heat control to maintain food quality and service timelines.

Project Background

This was a greenfield installation where the complete LPG infrastructure was engineered and deployed from the ground up.

Pune Gas implemented a LOT LPG system integrated with a Dry Type Vaporizer to handle high consumption loads efficiently. The system was further strengthened with LeakCheck integration and a fully designed pipeline network, ensuring safety, monitoring, and operational control across the facility.

The Challenge

Operating at this scale required overcoming multiple operational challenges:

  • Sustaining continuous cooking operations for 12,500 meals daily 
  • Efficiently managing LPG consumption of 5 to 6 tons per month 
  • Ensuring uninterrupted gas supply during peak kitchen hours 
  • Maintaining high safety standards in a large-scale environment 
  • Building infrastructure capable of supporting future expansion 

The Solution

Pune Gas deployed a fully engineered LPG system designed for high-demand institutional kitchens.

The solution delivered:

  • LOT LPG system enabling bulk storage with continuous liquid offtake 
  • Dry Type Vaporizer ensuring stable pressure and consistent gas flow 
  • Centralised gas distribution network for uniform heat across cooking stations 
  • Integrated LeakCheck system for continuous monitoring and enhanced safety 
  • End-to-end execution including design, installation, testing, and commissioning

Operational Impact

  • Uninterrupted Operations: Zero fuel related downtime across all service cycles 
  • High Volume Reliability: Seamless execution of ~12,500 meals daily 
  • Fuel Handling Efficiency: Optimised management of 5 to 6 tons LPG consumption per month 
  • Enhanced Safety: Continuous monitoring through integrated LeakCheck system 

Scalable Infrastructure: Built to support future demand expansion without system overhaul

Execution

The project was executed with structured planning, precision engineering, and seamless commissioning, ensuring a fully integrated LPG ecosystem without disruption to operational timelines.

Conclusion

The ICS Foods project at Tata Pegatron demonstrates how a well-engineered LOT LPG system combined with a Dry Type Vaporizer can transform large-scale catering operations.

By delivering a dependable, safe, and efficient energy backbone, Pune Gas has enabled high-volume food production with consistency and control. The integration of LeakCheck and a robust pipeline network further strengthens safety and operational confidence.

This project stands as a strong example of how the right energy infrastructure enhances productivity, consistency, and long-term scalability in high-demand environments.