ILLOVO Sugar South Africa’s Noodsberg Mill in northern KwaZulu-Natal is achieving operational excellence following a successful turnaround strategy implemented by Illovo Sugar South Africa (ISSA) and its parent company, ABF Sugar.
The mill has seen major capital projects in the past year totalling nearly R40 million. These investments delivered several successes during the 2023 crushing season. Notably, the mill achieved its lowest coal use in a decade while increasing refined sugar output. This was attributed to improved boiler efficiency, reduced bagasse moisture, and a more stable operation. For the first time in years, Noodsberg was able to consistently run on just three boilers instead of the usual four or five, ISSA said.
Noodsberg Mill also achieved an Overall Time Efficiency (OTE) best since 2015, Boiler House Recovery (BHR) best since 2018, and Refined Sugar Output best since 2017.
Noodsberg’s 11-week off-crop period proved equally successful and improved equipment reliability. During this critical maintenance window, the team completed significant prefabrication work in-house before the end of the 2023 crushing season, including vital components like crystalliser shafts and exhaust steam lines, and tanks. This proactive approach ensured a smooth start-up for the 2024 season on 8 March 2024.
Among the largest off-crop projects undertaken at Noodsberg were the 1B evaporator retube; RH Pan 1 Calandria replacement; maintenance work at the mill’s raw house; and the exhaust steam line replacement.
Noodsberg Mill’s general manager, Duduza Madlala credits the turnaround to several key factors.
- He said the mill implemented a laser focus on its two main boiler operations, introducing specialist engineers, including a boiler engineer, recoveries engineer, and production manager, to optimise boiler performance.
- Starting off-crop preparations earlier resulted in cost savings and in-house staff involvement in prefabrication work.
- Strategic off-crop maintenance and changes implemented through an operating model enhancement (OME) programme significantly improved equipment reliability and overall operations. The OME programme also focused on building a motivated and positive team culture that believes in the mill’s potential.
- The team proactively identified and addressed around 85 high-risk issues to minimise downtime during the crushing season.
Noodsberg Mill’s turnaround strategy has not only improved factory efficiency but also led to significant improvements in effluent management and stakeholder relations with growers and suppliers.
- About Illovo Sugar South Africa
ILLOVO SUGAR is a wholly-owned subsidiary of Associated British Foods plc (ABF), a diversified international food, ingredients, and retail group operating in 52 countries.
Illovo Sugar South Africa’s operations, based in KwaZulu-Natal, include the cultivation of sugar cane and production of raw, brown, and refined sugar and syrup. In addition to the company’s sugar business, it produces downstream products namely furfural and furfural alcohol, ethyl alcohol and lactulose.
