Building a Secure, Resilient IT Foundation for Himalaya Wellness’ New Dubai Manufacturing Facility

Case Summary

Himalaya Wellness needed a secure, resilient IT foundation for its new manufacturing facility in Dubai Industrial City. Intertec is delivering the greenfield environment as a turnkey engagement spanning the Mini Data Centre, campus network, wireless connectivity and perimeter security, creating a scalable foundation for reliable plant and office operations.

Business Problem

Himalaya Wellness needed an enterprise-grade IT environment built from the ground up for its new Dubai manufacturing facility. Key requirements included:

1. Resilient infrastructure: Secure Mini Data Centre with reliable power, cooling, fire protection and monitoring.
2. Plant-wide connectivity: Wired and wireless coverage across office, production, warehouse, BMS, QA and security areas.
3. High availability & security: Redundant ISP, firewall and core layers with segmented corporate, guest, voice, CCTV, biometric and IoT/BMS traffic.
4. Centralized operations & scalability: Unified visibility and sufficient capacity to support future growth.

How Intertec Helped

Intertec delivered the engagement as an end-to-end turnkey infrastructure programme, integrating the Mini Data Centre, passive infrastructure, campus network, wireless and security architecture.

The solution included:

Mini Data Centre & Passive Infrastructure

1. Datwyler Tier I, 10 kVA Smart Modular Data Centre with two 42U IT/network racks, in-row cooling and an electrical rack.
2. 10 kVA online double-conversion UPS with 9 kW usable capacity and 10–15 minutes of battery backup at full load.
3. 12.5 kW in-row precision cooling with humidification, filtration and emergency ventilation.
4. Monitored intelligent PDUs, surge protection and dual power paths.
5. NOVEC 1230 clean-agent fire suppression with smoke and heat detection.
6. DCIM monitoring with touchscreen/web access, SMS/e-mail alerts, and temperature, humidity, smoke, water-leak and door-status sensors.
7. Keypad access control integrated with the DCIM platform.

Campus Network, Wireless & Security

1. 2 × Aruba CX 8100 core switches forming the resilient MDF backbone.
2. 23 × Aruba CX 6100 access/WAN switches, including 20 PoE access switches supporting users, phones, cameras and APs.
3. 34 × Aruba AP-735 Wi-Fi 7 indoor APs and 25 × Aruba AP-677 Wi-Fi 6E outdoor/directional APs.
4. 2 × FortiGate-201G firewalls in HA for WAN security, NAT, segmentation and policy enforcement.
5. Dual-ISP, dual-firewall and dual-core architecture with redundant access uplinks.
6. Dedicated segmentation for staff wired/wireless, guest, voice, printers, CCTV/security, biometric, IoT/BMS, server/infrastructure and management traffic, with guest traffic physically and logically separated from the corporate network.
7. Aruba Central for centralised switch and AP monitoring, onboarding and lifecycle management.

Delivery & Governance

Intertec performed requirements validation, HLD preparation, capacity sizing, site-readiness checks, staging, installation, configuration, acceptance testing, documentation and handover.

The Mini Data Centre SAT was jointly witnessed by Himalaya, Intertec and Datwyler, while the network HLD establishes the baseline for detailed implementation, testing and final as-built documentation.

Business Outcomes Delivered

Single Turnkey Accountability: Himalaya has one integration partner coordinating the data centre, passive infrastructure, network, wireless and security stack, reducing multi-vendor handoffs and simplifying project governance.

Right-First-Time Mini Data Centre Commissioning: Electrical, UPS, power distribution, cooling, monitoring, alert and fire-suppression acceptance tests were completed in a single 5-hour witnessed SAT on 07 August 2026, with zero defects, zero deviations and no snag list.

Capacity for Future Growth: The 10 kVA UPS provides 9 kW usable power against a 3.1 kW design load, using approximately 34% capacity and leaving 5.9 kW spare capacity. The 12.5 kW cooling system operates at approximately 25% utilisation, providing around 9.4 kW of cooling headroom.

Resilient Enterprise Network Foundation: The campus design incorporates 2 core switches, 23 access/WAN switches, 59 wireless APs and 2 FortiGate firewalls in HA, supported by dual ISP, dual firewall, dual core and redundant access uplinks to minimise single points of failure.

Secure Segmentation by Design: Corporate, guest, voice, CCTV/security, biometric, IoT/BMS, server and management traffic are separated through dedicated VLANs and firewall policies. Guest wireless uses a separate firewall path, keeping it physically and logically isolated from internal networks.

Centralized Visibility and Operations: Aruba Central provides centralized monitoring and lifecycle management for switches and APs, while DCIM delivers real-time visibility into power, temperature, humidity, smoke, water leaks and door status, supported by remote SMS/e-mail alerts.

Future-Ready Wireless Coverage: The design incorporates 34 Wi-Fi 7 indoor APs and 25 Wi-Fi 6E outdoor/directional APs to support office, production, warehouse, outdoor and high-ceiling environments, with final RF optimisation validated during implementation.

Controlled and Safe Facility Delivery: Mini Data Centre implementation was completed with zero lost-time incidents, zero near misses and zero environmental incidents, supported by formal completion documentation, SOPs and handover records.