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Business Development Initiatives zamzam_KPZW_Components


King Abdullah ibn Abdul-Aziz Project for Zamzam Water


KPZW Components

Water Bottling Plant 

This plant consists of several buildings, including the air compressor building, bottled raw (unfiltered) water warehouse, production lines building and bottled water warehouse. The plant is built on an area of 13,405 m2 and contains 4 production lines with a maximum daily capacity of 200,000 10-liter bottles. 

Emergency Station 

The emergency station is made of reinforced concrete and bricks on an area of 1,200 m2. It contains the generator building, switchboard building, transformer building, in addition to 4 British Cummins generators with a total capacity of about 8 MW, and 3 other transformers. 

Zamzam Well Pumps 

Water is pumped from Zamzam well to KPZW at Kudai District through two giant pumps. 

Raw (unfiltered) Water Tank 

The raw water tank has a capacity of 5,000 m3, and is divided into two parts and made of reinforced concrete. 

Raw (unfiltered) Water Pipelines 

The pipelines transporting water from Zamzam well to KPZW, the lines transporting treated water from KPZW to the Grand Mosque in Makkah and other pipelines extending to Kudai reservoirs span a distance of about 11 km with 200 mm diameter. These pipelines are made of L316 stainless steel. Alongside these pipelines, there are compressor and washing chambers, and control rooms interconnected with special controls. 

Administration Building 

The Administration building is constructed on a total area of 752 m2 

Laboratory Building 

The laboratory is equipped with cutting-edge equipment for analysis and testing purposes and is managed by a highly qualified technical team. 

Raw (unfiltered) Water Pump Chamber 

The water pump chamber is made of reinforced concrete and bricks. It contains three water pumps; two for daily operations and one as a standby. 

Produced Water Pump Chamber 

The produced water pump chamber is made of reinforced concrete and bricks. It contains three pumps for produced water; two for daily operations and one as a standby. 

SCADA Control System 

All components of and operations at KPZW are monitored and controlled by SCADA System. 

Kudai Reservoir 

Kudai Reservoir is an old established reservoir. It contains a purification station and a pumping station, with a capacity of 10,000 m3. This Reservoir, together with the present pumping stations and control system, will be renewed, and have all its components connected to the new Project. 

Central Warehousing Project 

This warehousing project consists of a (58×42 m) central warehouse, with a height of 34m for the storage and distribution of 1.5 million 10-liter bottles. The project is fully automated using a state of the art storage and distribution system and is equipped with two overhead cranes, to meet the needs of pilgrims at peak times. The product pallets, each carrying (90) bottles, are transported from production lines via conveyor belts that link production lines to the carrier bridge which, in turn, connects the bottling plant with the central warehouse. 

The central warehousing project also utilizes the most up-to-date international storage system known as “Automated Storage and Retrieval Systems” (ASRS). Via this system, the pallets transported across the carrier bridge are sent back to the central warehouse using 2000 kg overhead cranes, and stored in specified locations that are managed and controlled by a state of the art storage program, where the pallets are stored by date and production line. 

​Upon completion of the production and storage operations, pallets stored in the central warehouse are moved to the automatic distribution system using overhead cranes. The program prioritizes sale and distribution operations according to the date of storage and the results of the produced-water tests conducted at KPZW laboratory. Finally, the bottles are transferred using the automated belts to 42 distribution points.