150x200x12m Egyptian Steel Espresso Production Facility

In November 2025, Xinguangzheng built a steel structure in Giza, Egypt, for an espresso coffee production line. Measuring 150 meters long, 200 meters wide, and 12 meters high, the facility covers 30,000 square meters. As a result, this space easily accommodates the complex needs of coffee production while meeting strict requirements from the start.

The facility supports roasting, grinding, and packaging coffee, but it also includes special features to handle Giza’s tough desert climate. With heat soaring up to 45°C, sandstorms sweeping in, and very dry air, protective measures are essential. These conditions pose risks to both product quality and machines. To address these challenges, the design keeps environmental threats in check, ensuring reliable operation year-round.

Customer Demand

Our client is Egypt’s top importer of fine Italian foods. They offer many traditional products, including hard and soft cheeses, canned tomatoes, and olive oil. All products come directly from Italy. Furthermore, their range keeps expanding as they seek new ways to meet customer needs.

The client maintains a strong reputation for high quality and strict hygiene standards. Through their commitment to excellence, their foods help restaurants succeed in a tough market. Moreover, they foster long-term relationships with partners. In addition to partnering, they provide ongoing sales support. With these services, customers can serve authentic Italian food and keep clients coming back.

For this project, the client sought a steel building dedicated to housing an espresso production line. By adding high-quality Italian-style coffee to their product list, they aimed to meet the rising demand in Egypt and neighboring regions. Additionally, the facility needed to be both large and food-safe. To ensure coffee beans remained fresh, it required a controlled environment that would keep dust out and maintain the ideal humidity.

Giza posed several challenges for the project. Not only did sandy winds blow in from the Sahara, but there were also minor earthquake risks to consider. Furthermore, the area demanded cooling systems that use less energy to manage the extreme heat. With all these factors in mind, the budget remained under 315,405 USD. The targeted delivery date, November 6, 2025, aligned with seasonal imports from Italy.

Following detailed talks and site checks, our team proposed a prefab steel design that would address all these needs. Instead of a standard approach, we chose strong framing paired with food-grade surfaces to ensure both durability and cleanliness. In addition, the facility features climate systems to keep the inside temperature steady at 20-24°C. To maximize efficiency, we arranged the layout with flexibility in mind, allowing for smooth production adjustments as required.

Solutions

For this project, Xinguangzheng relied on Q355B galvanized steel frames, which provided strength and resilience. Specifically designed to suit Giza’s location near the Nile, the frames helped address both climate and logistical needs. All components were produced in our Qingdao factory and then shipped by sea to Cairo. By adhering to ISO 9001 guidelines and meeting Egyptian food safety laws, we ensured both quality and compliance throughout the process.

To streamline logistics, we chose local roads for transport. Once delivered, our team bolted the parts together on site. As a result, assembly time was reduced and the workload in dusty conditions became much lighter.

Core Specifications

• Dimensions and Layout: The building is 150m long, 200m wide, and 12m high. It has open spans for flexibility. It is split into three areas: roasting/grinding (10,000 sqm), packaging (15,000 sqm), and labs/storage (5,000 sqm).

Structural Parts

• • Frame: Made of Q355B steel beams and columns. They are hot-dip galvanized and bolted. They can handle heavy loads from equipment.
  • Roof and Cladding: Uses 0.8mm coated steel panels with 75mm polyurethane insulation. Seals keep sand out, and reflective surfaces turn away heat.
  • Foundation: Piled concrete bases with anchors on packed sand. It includes extra support for seismic safety.

Custom Features

• • Hygiene: The floors are smooth epoxy. Key areas have stainless steel wall panels. Air filters cut down contaminants by 55%.
  • Climate Control: HVAC systems with humidifiers keep humidity at 45-55%. The roof is ready for solar panels to lower energy costs.
  • Access: Six large insulated doors (6m x 6m) for moving goods. Clean zones have airlocked entries.

Implementation Process

Construction of the facility took place in four stages over five months. Throughout the process, our team partnered with local builders who brought valuable experience in desert construction. As a result, each stage ran smoothly and on schedule.

1. Prefabrication (1 month): We made the parts in our workshop. This included galvanizing and wind tests.
2. Site Preparation (12 days): We built the foundation using local sand stabilizers.
3. Erection and Integration (3 months): The frame was put up in 20 days. Cladding and HVAC took 25 days. We added hygiene fittings in October when it was cooler.
4. Commissioning (1 week): The facility was handed over on November 6, 2025. We ran line tests and dust checks. We used 10% of the budget for extra seals to protect against storms.

Results

Since November 2025, the facility has consistently delivered impressive results. Notably, several key benefits highlight its success:

• Better Quality: The stable environment keeps the espresso flavor pure. This increased yield by 35% with no contamination.
• Cost Savings: The project cost 304,892 USD, which was 3% under budget. The insulated design cuts energy use by 28% in Giza’s heat.
• Durability: The building has resisted early sandstorms. It is built to last 40 years with little upkeep.
• Sustainability: The design is ready for solar power. This supports Egypt’s green energy goals.

At Xinguangzheng, we design specialized steel structures for food production across Egypt. If you need a custom metal frame workshop, reach out to our team today and discover how we can support your business.

Operations Manager:“We chose Xinguangzheng’s facility because it’s perfect for our espresso line. Not only is it spacious and clean, but it also stands strong against Giza’s challenging weather. Thanks to timely delivery on November 6, 2025, we can always protect our Italian quality standards. As a result, we’re able to deliver authentic tastes and build strong, lasting partnerships!