Laduma Dec 2022

L A D UMA INSIDE

GOING LIKE A BOEING

Message from the MD

I think we can all agree that 2022 has been a better year than the previous couple. Yes, we did have the devasting floods in April and the damage caused by these frustratingly continues to linger, but we seem to have moved on from Covid. The removal of restrictions and the freedom of movement regained makes you cherish something that you previously took for granted. Our use of available technology has increased exponentially with the use of Teams fully supporting our value of collaboration.

At the end of 2021 I wrote “I am looking forward to 2022, the construction and commissioning of the maize plant are behind us and the focus will be the continual improvement of operational performance. Everything we do will support and promote the key drivers of volume, quality, efficiency and competent, committed people. It is worth considering NCP’s purpose, “inspiring the realisation of potential through relationships to achieve extraordinary outcomes”.

2022 has been exactly that, we have continually increased daily production levels and in September achieved average daily production higher than the design capacity of the plant. The 12-month production till end October ’22 was a 50% increase on 2021 volumes. At the beginning of the year product quality was a concern and we sacrificed efficiency to achieve acceptable quality, we are now achieving our highest ever quality with continually improving efficiency. Overall sales volumes have increased 26% as own production replaced traded alcohol volumes with local and export sales growing strongly.

Unfortunately these achievements have coincided with the highest maize prices in South Africa’s resulting in tight margins. However, the solid operational base being set, with the continual focus on ongoing improvement, will stand us in good stead when commodity prices eventually soften and maize prices drop.

It is clear that our plant runs best when running at full steam, the focus for 2023 will be fine tuning for further optimization, with continually increasing daily production as best operating practices become embedded and routine.

To everyone that is part of the NCP family, thank you for your commitment to our values and purpose throughout 2022, please enjoy the festive season. Have great time, stay safe, be responsible and share time with your own families and friends.

Lucky’s legs carry him through a 6th Comrades marathon in 2022

mind

Lucky tells Laduma how he approached the 2022 ultra-marathon, a “down run” that started in Pietermaritzburg and finished in Durban, a distance of 90.2 km. “If you look back at 2020 and 2021, it was difficult because of the Covid-19 pandemic. I do however believe that my fitness and healthy body helped me with a strong immune system. “I started training for my 6th Comrades in December 2021 by preparing and running in the Two Oceans Marathon in Cape Town. It is a great marathon with a beautiful route and I really enjoyed it.

“When I started training, I weighed 110 kg, and after six months, I managed to lose 26 kg. I was happy and impressed with myself. “Running the distance of the Comrades, and being an ultra-marathon runner, you have to have a strong mind and physical fitness.

“I think it will be nice if everyone does maybe one Comrades in their lifetime, or if you don’t do that, maybe a 10 km or 21 km race, anything to keep your body fit, otherwise it will be easy to get ill. Our body is the only thing that we have, and the only thing keeping us going is a healthy body and a strong mind.”

Peter Starling, Managing Director

The motivation of a strong

and a healthy body has helped Lucky Ntuli, an Electrician to finish his 6th Comrades marathon earlier this year.

Lucky Ntuli (center) feels that our bodies are the only thing that we have, and that the only thing that keeps us going is a healthy body and a strong mind

fly. And according to her, they are well on their way to achieving that.“I’ve always equated a well-run chemical plant to flying. When flying, how often do you ponder about the workings of all the parts in an aeroplane engine? How often do you consider the intricacies of the travel routes that aeroplane companies around the world must have for the entire process to be so seamless?”

Kiara highlights 2022 and the “many phenomenal moments” the operations team achieved regarding safety, volumes, quality and efficiencies.

Milling capacity was previously restricted to a maximum of 28 t/h.

Following air leakage repairs, a capacity of 40 t/h has been proven.

Distillation operators have been vigilant in operating the distillery at the most efficient reflux ratios with close monitoring of the process using intermediate ethanol samples.

Producing beers with higher than design ethanol concentrations up to 17,5vol% versus a design of 15,5vol%.

Safety

With the support of the Alco Group, we have set the foundation for enhancing our safety culture such that it is practical, robust, and efficient enough to minimize plant downtime when undertaking maintenance and shutdown activities. This will become imperative in the future when more shutdown activities will run 24/7 to minimize downtime.

Fermentation operators have been diligent at making the “best beers” for the distillery controlling and monitoring the yeast propagations and fermenters using the new Near-Infrared Spectroscopy in their control room lab to ensure complete glucose conversion before feeding these beers to the distillery.

Fermentation operators have also focused on sanitizing the mash coolers, fermenters, and yeast propagator with manual Clean-In-Place cycles. The addition of chlorine dioxide to the cleaning regime has largely assisted in reducing lactic and acetic acid across the plant. There will be more work done here to reduce this contamination to industry standards.

Reduction in alphaamylase dosing in the liquefaction plant.

Since commissioning, the mash coolers have been a pain point for the fermentation operators being the single largest point of contamination in the plant as well as prone to gasket leaks and excessive downtime for modifications or repairs. In August 2022, the mash cooler gaskets and configuration were changed hopefully for the last time!

Introduction of a different start-up process which reduced the usual offspecification duration of 48 hours to 17 hours. This equates to a saving of approximately R1.5M per year, assuming 2x planned shutdowns per year.

Improving reboiler degassing to reduce the distillery operating pressure and steam consumption.

The time and effort of the operations team to master the Lock-Out-Tag-Out-Try-Out procedures have to be commended. The support of the maintenance team in streamlining the shutdown process is also greatly appreciated.

Due to uncertainty regarding future gas pricing, there has been considerable operator attention given to the water content in DDGS, wet cake, and syrup to save gas usage in the dryer. The operations team now runs 3x decanters instead of 2x to produce a drier wet cake. The improvement in wet cake has been from a design of 33% up to 40% dry matter depending on the rates. The introduction of viscozyme to improve the flowability of the syrup has enabled production to produce syrup in the range of 50 – 55% dry matter from an average of 40 – 45%. The improvement in syrup dry matter only equates to a saving of R2,5 million per year.

Introduction of copper to the distillery to remove sulphur.

Wellness Casual Day

Launched in 1995, Casual Day is an awareness and fundraising campaign benefiting the National Council of and for Persons with Disabilities (NCPD). Each year, South Africans are encouraged to dress up and

Casual Day 2022 took place on 2 September and AlcoNCP combined the occasion with a Wellness Day, presented in cooperation with Discovery Health. Employees took this year’s Casual Day theme of #icelebratesawithpersonswithdissabilites to heart and dressed up in the colours of the national flag.

During an interactive experience, various tests and health checks were performed by a wellness expert from Discovery Health. These included glucose and cholesterol tests, blood pressure readings, eye and postural assessments and BMI (Body Mass Index) measurements. A comprehensive report with advice on how to address certain risks was subsequently shared with the individual staff members.

Women’s Day: “Embrace change”

August is Women’s Month in South Africa with National Women’s Day on 9 August, celebrating the strength and resilience of women and their contribution to society and the country.AlcoNCP joins the celebrations each year, and 2022 was no exception. Following the lifting of Covid-19 restrictions, it was wonderful to once again come together and to re-awaken the company’s Women’s Day festivities. This year’s theme was “Transformation” and the journey every woman takes as she progresses from a little girl into womanhood. Siphokazi Majozi, production manager of secondary products at AlcoNCP, was the speaker at an interview-style Women’s Day function.

She shared some insight into her transformation journey and the different roles she’s played in her life, from mother to author to runner, who has attempted the Comrades marathon and writes a successful running blog. Siphokazi interviewed Janet Simpkins, an environmental activist who started Adopt-a-River Eco Solutions, a non-profit organisation focussing on community-based solutions to some of the river health issues in KwaZulu-Natal. Janet, who writes on her website that her desire is “to leave a better planet for my children and humanity to come”, had a clear message when speaking to Siphokazi - embrace change.

Our projects team members Lumeshni Pillay, Kaylin Naidoo, Leeandra Sarjoo and Lavania Govender feeling patriotic with our South African flag

Taking time out to celebrate woman’s day with speakers, Janet Simpkins and Siphokazi Majozi (far right) are Judy Somers, Lorraine Haripersadh, Sarisha Ramsunder and Nikita Ajodha

Simangele Ndlovu seen celebrating Casual Day to raise awareness for persons with disabilities

Showcasing our beautiful Zulu clothing and colours are, Mzo Jama, Lungile Makhanya and Nomvula Njapha

AlcoNCP have upped its health game to incorporate personalised health and fitness plans for employees. The Health and Fitness Initiative, in collaboration with coach Ilizme (May) Coetzee from May-Nia Fitness, will see the development of individual plans for registered employees. Coach May says the fitness programme will have a great impact and overall positive outcome. “The staff members have been amazing and very keen on bettering their lifestyle. From the check-in conversations held with some of the members, they all had a general issue with making time at home to train. But they have all been amazing at trying to find their way of staying active and pursuing their fitness goals.”

Risk and compliance manager Lorraine Mudaly: “A great number of staff have signed up for the programme. And the benefit is that coach May has worked out meal plans and home workouts. Now I have the flexibility to follow the programme in the comfort of my own home. A journey starts with the first step and it will take time to get there, with small steps. Set mini-goals to achieve the long-term goal.”

Procurement officer Nikita Ajodha: “My sessions with coach May have been awesome, I feel energized! I have missed a couple of sessions between having the flu and keeping up with work demands but I can say that it's made me realise that I need to do more for myself, in terms of exercise and nutrition. I have been able to make more conscious decisions about my nutrition and I find myself wanting to move more, taking the stairs instead of a lift, parking a little further from the entrance to a store, it’s the little things matter.”

Messenger Ntombi Tukwayo: “I found myself in a better mood, I think more clearly and remember better, my bones became stronger, and my body also responds better to insulin which lowers the risk of diabetes. Eating well helps to reduce the risk of physical health problems.”

Funds and creditors controller Xolile Mabaso: “I do enjoy Fitness Friday and I always look forward to it. I'm now flexible and able to breathe properly under any circumstances. The home exercises help a lot, I am having fun with my daughter when doing them.”

Quality technician Rashina Munsamy: “I have definitely noticed a huge impact on our training sessions. I feel more energetic than I ever have and I’m also getting more disciplined in my exercising. I feel I can now keep up with the busy lifestyle we lead.”

Mandela Day 2022: “It takes a village”

Mandela Day is celebrated each year on 18 July, the birthday of the former South African president, and is a testament to Madiba’s life and legacy. On Mandela Day, South Africans are encouraged to spend 67 minutes of their time in service to others in need. These 67 minutes are in appreciation of the 67 years Mandela spent fighting for justice, equality, and human rights for all. This year AlcoNCP celebrated Mandela Day with SAPS Greenwood Park during an outreach programme that included the local Community Policing Forum and Business Against Crime. Community Safety awareness flyers were handed out to members of the public at China Mall and Spar Browns Drift for 67 minutes.

On the day, Laduma spoke to bystanders at the two locations about the importance of community outreach initiatives on Mandela Day. The overall consensus was that crime doesn’t pay: “Drug abuse is very high in South Africa, it is very sad to see our brothers and sisters involved with something like this.

Engineering manager Morgan Murefu and financial executive Mark from AlcoNCP said it was great to finally step out for Mandela Day once again after the Covid-19 pandemic. “I feel connected to the human race once again. They say it takes a village to raise a child but it is more than just raising a child, it is bringing up a human being, and by doing this, we are really caring for one another. “We are all doing our bit in helping the police to let the community live responsibly.”

Morgan Murefu and Mark Norton-Amor joined the Greenwood Park police station during this year’s Mandela Day to raise awareness for crime prevention by handing out educational pamflets at local shopping centres

Safety doesn’t happen by accident

“Every accident is a notice that something is wrong with men, methods, or material. Investigate, then act”. The author of this piece of advice may be “Unknown”, but it is a timely reminder that workplaces must be secure and employees must be alert at all times. AlcoNCP is no exception. Compliance officer Dineshree Pillay took some time to lay out the minimum Personal Protective Equipment (PPE) requirements to Laduma. The only thing to remember is that safety first is safety always. Workplaces must be secure, and employees must be alert at all times. “Specific PPE will be required for certain high-risk areas or high-risk jobs. For example, ear plugs will be needed if you're entering high noise zones such as maize offloading, or boiler house. If you’re doing work in areas where you could be exposed to hazardous chemicals such as sulphuric acid, you need to wear appropriate acid-proof overalls or suites, face shields and acid-proof gloves. It's also important to note that people who wear glasses are required to wear over specs when working in plant areas.

“When you’re working at heights you’ve got to have a safety harness.” Dineshree also pointed out the responsibility of AlcoNCP when it comes to visitor and contractor safety. representative to ensure whoever they bring on site, is safe and has the appropriate PPE, whether it be reflectors, reflector jackets, hardhats and goggles. We also have and safe accompanied by someone from AlcoNCP.” Referring to two recent incidents in which a plant operator injured his eye and another in which an employee sustained minor burn wounds, Dineshree said there’s been far too many of these.

“We see people are rushing a lot of the time, there is a lot of pressure and people do tend to take shortcuts. This is a reminder, we cannot take shortcuts. It will take you maybe a minute or two longer to do a risk go and get the right PPE and do the ”According to Dineshree a lack of knowledge is the reason lockout procedures aren’t followed correctly.“It is a lack of and also maybe the risk perception. If you’ve done something for maybe many years or if you’ve done it over and over again and nothing happened, you tend to feel that nothing is going to happen. There has therefore been a lot of training and trying to change the way people think. “We always say one lock, one life.

Every person that has to work in an area where they could be exposed to hazardous equipment, equipment starting, or hazardous material from lines must follow the lockout procedure. “When we started rolling out the lockout training, we found there were people who didn’t understand that every person needed to lockout or why. Slowly the thinking is starting change, and people are beginning to understand why it is so critical. “We have used our toolbox talks to re-enforce the lockout procedure.”

Our minimum PPE requirements if you’re entering client areas include safety boots, hard hats, reflective vests or overalls and safety glasses.

AlcoNCP’s audit results

AlcoNCP have two major audits each year. The IMS audit encompassing ISO 9001, 45001 and 14001, as well as the FSSC audit (food safety). This year’s IMS audit took place on 27 June and also served as the recertification audit, a process that happens every three years. According to compliance officer Dineshree Pillay, the recertification audit was a major event but AlcoNCP managed to secure it once again.

“There were nine minor findings that were noted and we’ve logged these onto our IO system to be addressed. ”

Projects: Multiple pump replacements

As a leading producer of high-quality neutral alcohol and Distillers of Dried Grains with Solubles, here at AlcoNCP we constantly strive to improve our performance. Process technician Lavania Govender and project manager Lumeshni Pillay report back on various pump upgrades, degassing and the copper pot installation in the setting of standards in service.

Pump upgrades

PMP530

The motor on the purified alcohol pump in the distillery was upgraded from 22kW to 37kW. This modification was required for debottlenecking as pump capacity was limited to 80% speed on the drive. Since this change, the pump speed has increased up to 85% on normal operation without concerns for trips.

PU014 and PU015

The acid condensate recovery pumps were replaced with larger DURCO models on a variable speed philosophy to maintain a level in the acid condensate tank. The old level control valve was removed as this posed a restriction on recovery flow rates. These pumps can recover up to 50m3/hr, which is double the original proposed duty. Increased recovery in acid condensate reduces the amount of fresh corporation water required to maintain levels in the acid condensate tank.

PMP490

The rinsing effluent pump was deemed inadequate to handle the solids in TNK490 and as a result, frequent blockages occurred. PMP490 was changed to a SAMCO pump with an open impeller and larger motor. The modification included a recirculation line to the tank and an isolation valve to effluent to ensure that solids remained in suspension. Since the change, callouts regarding ‘unblocking lines’ have decreased and solid recovery to TNK310 has been a priority.

Degassing and copper pot installation

Degassing in a distillery is essential for removing non-condensables. The lower degassing on TNK550A/B, HTR530 and HTR540A and B were ineffective due to a design flaw which caused reduced heat transfer efficiency in the reboilers hence more energy usage, and column pressurisation. A modification of the degassing system was done in August and October, resulting in degassing flows increasing by 5ton/h, and pressure reduction in all columns. The nosing results after the copper pot were installed were distinctly better and the nosing profile across the distillery has since changed to more sweet, fruity and pleasant odours.

Operator Training: AlcoNCP operators taking it all in their stride

It is said employees who are properly trained are more familiar with the requirements of their position resulting in increased productivity. This is exactly the feeling of the production specialist at AlcoNCP, Zinhle Mqadi. “Task books was an idea from the Ghent plant guys because it has helped them over the years to train their staff. There was quite a lot of translation that needed to be done and then we also had to adjust the task books to our plants. “In our task books, we have all these practical questions and theoretical questions that are relating to the different areas of the plant, to try and get a better understanding of certain areas of the plant and what would you do if something happens. It also tests whether you know what the parameters and specifications are.“It starts with practical issues but also covers the the oretical issues, like the formula of some of the chemicals that you use.”

Zinhle says operators and shift managers greatly benefit from these task books. “The biggest job for the shift managers is to do every part, which is all four parts of the plant. But the operators are only focussing on the areas that they are working on the front-end field operator, front-end panel operator, back-end field operator and back-end panel operator.”According to Zinhle in-depth training is of great importance at the AlcoNCP plant.

“The plant is larger and much more complicated and studying is therefore very important. Just opening and closing valves are not good enough anymore, you’ve got to understand why you have to do certain things, so training is essential. “Before we used to just make sure that people followed instructions, but now we want people to think, to sit and think about what is going on here and then make decisions. Avoiding breakdowns, mistakes and safety incidents are all included.” I’m very proud of the operators and the way that they’re taking everything on. “At AlcoNCP, we are here to build and motivate each other, you have to do that.”

Production specialist Zinhle Mqadi (left) going through his taskbook with field operator Chapi Elellwang (right)

Process technician Lavania Govender at one of the pumps that was repaired to ensure improved plant performance

AlcoNCP join hands with Adopt-A-River and Fish Eagle for environmental rehabilitation

AlcoNCP contributes towards the social development of communities in the immediate areas surrounding the distillery. A great emphasis is placed on education, particularly in the fields of mathematics, science, engineering, and conservation education, as well as the social well-being of communities.

AlcoNCP recently joined Adopt-a-River Eco Solutions, a registered non-profit working in the river and environmental space whose focus is on community-based solutions to the myriad of river health issues

World of Work Career Fair: Taking a WOW look at the world

The Durban University of Technology (DUT) hosted its annual World of Work (WOW) Career Fair on 5 and 6 October this year. Around 100 companies were hosted by DUT offering insights into the world of work after university. It was a great opportunity for attendees to build their network and cement their capabilities and skills as DUT graduates.

handful also manned the AlcoNCP stand at WOW and Laduma spoke to them about the

According to Leeandra Sarjoo process in-service trainee, there was great interest in AlcoNCP’s in-service training programme and other opportunities at the

QAQC in-service trainee Alicia Chetty said the WOW career is important to showcase the in-service training positions available at AlcoNCP. “I’m studying analytical chemistry and doing my in-service training at AlcoNCP

Part of my in-service training comes with a chemistry project which I have to complete in the AlcoNCP lab. This will then become a presentation that I have to present at DUT at

Electrical in-service trainee Mncedisi Mtuli said one should never give up hope. He credited his high school English teacher, Mr Singh, with laying the foundation of this

The immediate outcomes of the Adopt-a-river project are the maintenance of the road verge and clearing and maintaining a security walkway between AlcoNCP’s property and the natural bush along the Umgeni riverbank