L A D UMA
Peter Starling, Managing Director
During the year we have regularly referred to our value stream mapping initiatives, originally focussed on maize offloading and DDGS loading, moving on to alcohol loading procedures. In my last Laduma message, I highlighted that these would eventually be applied to every aspect of our business, we would examine our current methods; providing an opportunity to reimagine how we work.
The “Reimagining Excellence” initiatives aim to redefine how we approach excellence across our entire organization. Our intention is to evolve our processes, enhance our efficiency, and sharpen our focus on delivering value to our customers and stakeholders.
As AlcoNCP has grown, so too have the challenges and opportunities before us. Our customer base has expanded, our markets and competitors have evolved, and sustainability and good value are the priorities. We've built our reputation on unwavering quality and attention to detail. Now, it's time to reimagine how we maintain that while adapting and aligning with the new market realities. This isn't about compromising our standards, processes and procedures; it's about being smarter in how we apply them. We need to consider how we can simplify not just our production processes, but also our administrative and financial functions as well. This approach will allow us to be more cost-effective, responsive, efficient, and adaptable in an ever-changing business landscape.
Opportunities for improvement are everywhere in our organisation. For example, this issue of Laduma highlights two departments' journeys toward a paperless environment, focusing on streamlining, reducing waste, and improving efficiency—key elements of “Reimagining Excellence.” However, with this edition of Laduma still in print, it presents a chance for further streamlining. That’s why we’re announcing that this will be the final printed edition. Since 2006, Laduma has brought joy to its readers (in print), but times are changing. To align with our "Reimagine Excellence" initiative, future issues will be digital, allowing us to better meet the company’s evolving needs while supporting sustainability.
The desired outcomes for the company of “Reimaging Excellence” include streamlined processes, especially where they involve multiple departments; better understanding of cross-functional activities and improved inter-departmental teamwork; reduced complexity; optimised administration functions and increased use of data analytics for decision-making.
As individuals this should lead to more autonomy in decision-making and problem-solving within your areas of expertise, increase collaboration and knowledge sharing and opportunities to learn and grow. Your ideas and feedback will play a crucial role in our ongoing refinement of processes.
Remember, "Reimagining Excellence" is not just a slogan – it's a commitment to evolving together, to being smart in our approaches, lean in our operations, and focused on what truly matters.
ISCC RE-CERTIFICATION SUCCESS
In reflecting on the recent ISCC re-certification, Rodgers Niranjan, procurement manager, highlights how the procurement team has been deeply involved in the company's journey toward sustainability. This achievement holds great significance for the company and the entire network of farmers and stakeholders dedicated to sustainable practices. In July 2024, we successfully passed our ISCC re-certification audit, conducted by the Control Union, without a single major finding. This flawless audit ensures that we remain the only certified sustainable ethanol producer in Africa. It’s a testament to the hard work and dedication of all involved—from our production teams to our network of certified farmers.
The certification allows us to continue sourcing sustainable grain and supplying ethanol to the European fuel market, which is critical to our ongoing operations. This continuity is vital for keeping our plant running smoothly and contributing to the global push for cleaner energy.
Cover: Ace Govender, AlcoNCP’s quality manager was spotted taking samples in a maize field
ISCC RE-CERTIFICATION SUCCESS (cont.)
Our collaboration with the Alco Green team has been key to this success. In-depth emission studies and farm audits have played a big role in ensuring that we meet the stringent ISCC requirements. This year, five farms were randomly selected by the auditor for inspection, and once again, we passed with flying colours. One thing that stands out for me is our commitment to reducing our carbon footprint. This year alone, we’ve reduced our plant processing emissions by 12%, thanks to more accurate steam consumption values during dehydration. We’re also exploring the possibility of transitioning from fossil fuels to renewable energy sources in our operations, which could further drive down emissions. Another area of innovation is soil carbon accumulation. Our certified farms are practising regenerative farming techniques like no-till farming, crop rotation, and cover cropping. These practices help increase the organic carbon content in the soil, which effectively locks away carbon dioxide—a key greenhouse gas. As we look to the future, our focus remains on continuous improvement. We’re committed to further enhancing our sustainability practices, exploring innovative ways to reduce emissions, and supporting the farmers who make it all possible. I would like to extend my gratitude to everyone involved in this achievement, from the Alco Green team and production staff to our partner farmers and the Control Union auditors - because together we are setting the standard for sustainability in our industry.
The AlcoNCP laboratory team has been instrumental in this effort, collecting and analysing soil samples to track progress. Seen here with Ace Govender is Senzo Mtshali, lab technician, out in the maize fields collecting samples—a rare sight considering they’re usually in the lab, dressed in their white coats.
OUR NEW NOSING PANEL TRAINEES
In a significant move to strengthen our quality control processes, colleagues from various departments have volunteered to undergo training in the essential skill of nosing. These trainees are currently honing their sensory skills under the expert guidance of Ace Govender, our quality manager. He remarks, “ A diverse pool of proficient nosing panel members is vital for maintaining and enhancing the quality of our products. Each trainee brings unique insights and perspectives from their respective departments, enriching the panel's overall expertise. We look forward to the positive impact this expanded nosing panel will have on our commitment to excellence in every product we deliver.”
We are pleased to introduce the new members of our inter-departmental nosing panel they are (fltr), Timothy Moodley, SHEQ officer, Lucy Matthews, funds and creditors, Lumeshni Pillay, projects manager, Nikita Ajodha, procurement officer, Dineshree Pillay, SHEQ compliance officer, Verushka Sewraj, creditor controller, and Kaylin Naidoo, project technician
REVOLUTIONISING THE NOSING PROCESS
AlcoNCP has pioneered an innovative leap in alcohol quality control with the development of an electronic nosing wheel. Designed to enhance accuracy and efficiency, this cutting-edge tool promises to transform how the company evaluates product quality. Operations executive, Stephen Kitching and Shon Roopnarain, control systems engineer, share insights on the origins and technology behind this breakthrough.
The Journey Begins – Stephen Kitching
The electronic nosing wheel arose from challenges after switching to maize-based alcohol, which introduced more complex scent nuances compared to molasses-based alcohol. "Understanding these new nuances and defining what was acceptable became a challenge," recalls Kitching. Subjectivity in the nosing process often led to unnecessary adjustments with potential cost implications.
To address this, the team explored ways to remove human bias and improve reliability, leading to the discovery of nosing wheels for scent categorisation. "Making it electronic was the next logical step," says Kitching, aligning with AlcoNCP's LEAN goals by eliminating inefficiencies like paper waste and manual data transfers. (continue pg. 4)
Managing director Peter Starling (left), Control systems engineer and nosing wheel project leader Shon Roopnarain (centre), and Operations Executive Stephen Kitching in the company’s nosing room, at one of the five tablets available for capturing nosing panel scores on the new nosing wheel application
REVOLUTIONISING THE NOSING PROCESS
(from pg. 4)
The Technology Behind the Breakthrough – Shon Roopnarain
Shon Roopnarain spearheaded the technological development of the electronic nosing wheel, the first of its kind globally. The wheel integrates several digital features, including:
Digital Nosing Wheel: A fully digital solution replacing paper-based scoring.
Digital Booth Setup and QA/QC Sample Viewing: Streamlining processes that were previously manual.
Automatic Workflows and Documentation: Eliminating the need for manual document handling.
SharePoint Integration and System-Based Emails: Automating communication and file uploads.
Developed using a C# code structure, the system provides robust functionality with zero ownership costs and error-checking at every step. The transition to the electronic nosing wheel has cut nosing time in half, with samples now scanned and scored in under two minutes.
Efficiency Gains and Agile Development
The development followed an agile approach, involving key stakeholders early and allowing users to learn the system incrementally. This seamless training minimized the need for formal instruction and integrated the tool into daily workflows.
Future Upgrades and Key Contributors
The electronic nosing wheel will continue to evolve as AlcoNCP refines its use. Roopnarain anticipates further enhancements, with future versions expected. The project’s success stems from a dedicated team’s thorough engineering, relentless pursuit of excellence, and focus on user-centered design. This revolutionary tool not only represents a technological leap for AlcoNCP but also sets a new global standard for the industry, transforming the way alcohol quality is evaluated—efficiently, accurately, and with unparalleled precision.
Staff engaging in testing the nosing wheel during its recent launch
Lumeshni Pillay, projects manager
Kaylin Naidoo and Lavania Govender, project technicians
Sherlene Moodley, quality technician
Nomvula Dlamini, senior quality technician
TWO TEAM'S PAPERLESS JOURNEY
The Distribution & Compliance Team has made significant strides in its paperless initiative, aligning with the company’s LEAN principles. This shift has streamlined processes, reduced waste, and improved efficiency. Lorraine Mudaly, distribution and compliance manager, highlights how the move to digital has cut administrative costs and supported environmental goals. Tools like SharePoint, OneDrive, and D365 have optimised workflows, while electronic document stamps, developed with Ryan Whittaker’s help, have further reduced manual tasks. Looking ahead, the team plans to implement vendor invoice approval workflows to continue their paperless journey.
The Distribution and Compliance Team, celebrating their progress in the paperless journey, captured together during the company’s recent Casual Day event
The Laboratory Team is also transitioning to a paperless system, primarily in its quality assurance (QA) processes. Senior Quality Technician Nomvula Dlamini explains that limited physical storage and the need for better data accuracy drove the change. Going digital has reduced storage issues, improved efficiency, and cut costs by minimising printing. The new system enhances accuracy, traceability, and communication, allowing for quicker access to records and faster test result delivery.
Siyabonga Nkosi, laboratory in-service trainee, calibrating a pH meter during the morning routine. Previously, calibration sheets were handwritten and bound for a year. Now, the results are digitally recorded on SharePoint as part of the paperless initiative.
SAFETY READINESS
During the recent plant shutdown, the SHEQ team held an emergency drill with eThekwini Fire and Rescue Services. The drill involved rescuing 'Studla,' a safety dummy, from a confined space to test the company’s emergency readiness. According to Timothy Moodley, SHEQ officer, the simulation was a success, completed in 30 minutes, and highlighted key learnings like improving medical response times. This exercise is part of the company's ongoing commitment to safety and preparedness for high-risk scenarios.
‘Studla’ is pictured here with his rescuers, Timothy Moodley and participating eThekwini Fire Department members, showcasing the successful joint effort during the emergency drill
PRODUCTION ACHIEVEMENTS & FOCUS
In a recent TuneMe staff meeting, Kiara
Additionally, new molecular sieves for
“The
production team is well-prepared for future success through a focus on cross-training, process optimisation, and effective cost management.”
Siphmandla Buthelezi Thandeka Khuzwayo Senzo Luthuli Nandi Ndawonde
MANDELA DAY
On July 18, 2024, our team united for Mandela Day, laying the groundwork for two JoJo water tanks at Sea Cow Lake Secondary School. Employees formed two groups to compete in mixing concrete and filling the brick bases, playing a crucial role in improving the school's water supply challenges. As Acting Principal Vineshree Naidoo highlighted, “With the two new water tanks and pumps, our doors can stay open, allowing our learners to focus on their studies uninterrupted.” This initiative not only enhances access to water but also ensures the school remains operational.
HERITAGE DAY
CASUAL DAY
Every year, AlcoNCP celebrates Casual Day by donning company-sponsored stickers in support of the Association for People with Disabilities. This beloved tradition encourages team spirit while promoting awareness and inclusivity. This year's theme, "I See You – Tell the World Who You Are," urged everyone to look beyond appearances and appreciate the true essence of each individual
Celebrating South Africa's rich cultural diversity on Heritage Day: Colleagues Verushka Sewraj (left) and Nikita Ajodha (right) proudly donning their traditional attire.
In this vibrant photo, we see Renisha Joseph (left) and Ryan Whittaker (right), customer services controllers (export) next to Jacqueline Haynes, receptionist embody the spirit of Casual Day as they express themselves and share their unique identities with pride.