December 2020
Message from the MD
NCP Operations: 2020 Covid-19 presented Operations with unique challenges, but also opportunities, writes Gary Bregovits. During the early phases of the lockdown the focus was on the safety of personnel, where direct interaction between members was limited, but without limiting overall communication and effectiveness.
Peter Starling, Managing Director 2020 was the year no one expected, it was the year we were shown that everything we took for granted could be changed by something we couldn’t see, couldn’t wish away and couldn’t pretend wasn’t there. In that same year NCP has achieved a record month’s production, delivered 10,000kl of alcohol for sanitiser production, kept the NCP100 project on track and achieved excellent financial performance. We have learnt the benefits of video conferencing, run our own virtual learning programs, written exams remotely, some of you have even become stars of our in-house Tune Me videos. The performance and commitment of every single member of NCP has been exceptional, you have retained your focus on the right things, you have not allowed yourselves to become distracted and you have adapted to everything that the world has thrown at you this year. I am extremely proud to be part of the NCP team, you have all made a significant difference.
Excellent collaboration between Commercial and Operations resulted in converting the concept of hand sanitiser into a realizable product that met a number of stringent requirements. Sourcing of the requisite raw materials, providing the required formulations and enabling the conversion of plant, resulted in good volumes of the product being made to meet customer requirements. This helped to sustain NCP in the first few months of the lockdown, during which the business was deemed an essential service. A second highlight was the sustained good production and efficiencies achieved through the year. Again, there were many contributing factors from an energized team. These included: • The creativity and motivation of all our personnel. • Sourcing of high test molasses (HTM) to supplement our molasses supply. • Continuous improvements made over the years. • Focus on uptime, through effective decision making and excellent maintenance practices. • Managing the evaporators, which are the constraint of the plant – this involved attaining good beer strengths and rigorous cleaning practices. By October, the production had exceeded the budget by 7409 kls AA, with a daily production record of 178.2 kls AA being achieved in September. After an overall successful year, the coming festive season is a time for relaxing, reconnecting, reflecting and recharging for the exciting challenges of 2021.
We have less than four months left producing alcohol from molasses, in March 2021 we will cease molasses processing and by May we will have completed the conversion to maize. What seemed very far away a couple of years ago is now just around the corner. The challenge will be to take the book learning we have done this year and apply is to an operational plant. This is a new experience for all of us, and while daunting, it is also extremely exciting and will change NCP forever. The processing of maize presents opportunities that molasses did not, the abundance of raw material means that plant capacity will not be limited by raw material, and the focus on maximizing production will be our priority. We have already commenced feasibility studies on two additional projects which would add further products and capacity to our range. To everyone that is part of the NCP family, please enjoy the festive season. It will be different this year, COVID is still here and we all need to play our part in limiting its damage, but at the same time we still need to recharge our batteries, take some time to relax and prepare for next year. Have great time, stay safe, be aware of potential spreader events and get ready for 2021, it's going to be a big year.
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Pictured in front of the new silos during the NCP100 practical training for Operators are (back row from left) Smangele Ngubane, Tazmyn Gounden (NCP100 trainer), Siphamandla Buthelezi, Nomsa Mabaso; (front row from left) Arthur Ndaba and Logan Govender
Star Troopers Bow Out It's time to say farewell and a heartfelt thank you to four long serving members of the NCP team. Zeph Mhlongo, Wilson Madlala and Hezekiah Zungu all retired in the second half of 2020, while André van der Westhuizen will be doing so at the end of the year. André van der Westhuizen, Systems and Compliance Executive, will retire at the end of 2020 after four decades in the industry. “My association with Sentrachem, predecessor of NCP, started in 1980. In 1983, NCP in Johannesburg offered him a job as Senior Microbiologist. A year later he was Group Head Microbiology Research. A number of promotions followed before he was transferred to the Durban plant, where he became Production Manager Alcohol products in 1989. In 1991, he was back in Germiston as Principal Biotechnologist, and later became Business Development Analyst. In the first decade of the 21st century, he carried the title of Business Challenger at NCP in Durban. From 2013 to 2016, Andre was the Supply Chain Executive, managing the end-to-end NCP supply chain and coordinating planning processes, including evaluation and monitoring of business compliance systems. He will retire as Compliance and Business Process Executive, a position he has held since July 2016. “It has been great working for NCP”, says Andre. But at 65, he is ready for a new phase. True to his journey, he will seek and find new avenues. “NCP has been a huge part of my life. My family have long complained that I live, eat and sleep NCP. It is time for a new chapter.” He is glad that he’ll have more time for photography and for his six grandchildren. “The other day I was working on my computer and my three-year old grandson asked: ‘Grandpa, did you forget it is the weekend?’” …thank you to mentors “When I started, out Dan du Toit was my manager. I always remembered that he said your qualifications get you a foot in the door. But to succeed, determination, passion and hard work are needed. I also appreciated the trust and mentorship of John Counihan in accepting me in the planning department as a business analyst - a good foundation for the rest of my time at NCP. It has been a pleasure working with Peter Starling. He allowed me the freedom to explore and investigate different areas of strategy and business process for the company’s benefit.”
Zeph Mhlongo retired as Office Assistant at the end of June as one of the most adored faces at NCP. Visitors from wide and far would first ask if Zeph was around before asking for their host, on account of the phenomenal cappuccinos he served during meetings. Zephie (as he is fondly referred to) retired at the end of June 2020 after 32 years of service. He has returned to his hometown, close to Gingindlovu in Zululand, where he spends his days with his family and grandchildren. Wilson Madlala retired from his position as Stores Assistant at the end of October, after 40 years of service. Willy, aka “Kumaren Naidoo” as he named himself, had this piece of parting advice for his friends and colleagues: “You must respect each other, and never mind the small things.” Wilson understood customer service and was passionate about his job. His take on dealing with people is that you must have respect for others, always. Hezekiah Zungu retired as Operations Controller at the end of October, after 36 years’ service. According to Hezekiah, he worked in every single department at NCP except Engineering. This quiet man is quoted by his colleague, Siphokazi Majozi,as saying, “You have to learn the art of perseverance, and remain focused and open to learning and changing all the time.” A few years ago, when new environmental bylaws necessitated a change in operations at the Effluent Plant, Hezekiah was involved in writing up Standard Operating Procedures (SOP's) from scratch. These have since been used for training, In addition, he mentored Chemical Operations learner students on their 3-year training programme, and was a key contributor in pioneering the electronic log sheets that have contributed to the effective monitoring of plant processes. LADUMA December 2020
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Training Tops the Bill at NCP Training the next generation of talent will always be a priority at NCP Alcohols. Notwithstanding the impact of the Covid-19 pandemic and lockdown, this was as true in 2020 as it has been in previous years. Laduma chatted to the bright students, past and present, who began - or are in the process of beginning - their careers as in-service trainees and apprentices at NCP’s Durban plant. Former Process Engineering students in training, Tazmyn Gounden and Kuben Naicker, now both training manual developers on the NCP100 project, tell us about their respective journeys at NCP. Tazmyn, when did you join NCP? In January 2019.
When did you join NCP Kuben? I joined in July 2019.
What did you study and what was your in-service position? I completed a BSc (Hons) in Chemical Engineering and worked as the chemical engineering in-service trainee in the projects team.
What did you study and where? I obtained a BSc (Hons) in Chemical Engineering at UKZN.
Most memorable moment/time of your in-service year? I was lucky to be here at the beginning of the NCP100 project and gained valuable experience, working with and learning from many different departments. What is your current role at NCP? I am an Assistant Projects Technician for the NCP100 project. I love being involved in all the workings of a major site project. Tazmyn (at the screen) and Kuben (far right) conducting NCP100 operators training with operations controllers, Nkululeku Mseleku (far left) and Selby Zungu (middle)
What is your current in-service position? Chemical Engineering/Project Management Trainee.
Tazmyn (left) and Kuben (right) with their training mentors and moderators, Lumeshni Govender and Lavania Govender. Lumeshni and Lavania are Process Technicians and key stakeholders in the NCP100 project
Tell us about your role as a training material developer on the Move to Maize Project, I compiled four modules ranging in difficulty/scope for the operations and engineering staff. The modules have been designed to ease staff into the workings of the new plant and build up their knowledge of operating it. Your future ambitions? My experience in the Projects department has inspired me to pursue a career as a project manager. I hope to obtain my certification as a certified associate in project management next year.
Your first impression on arriving at NCP? It was amazing. This was the first chemicavl plant I had the opportunity to work on, and I was welcomed by everyone from day one. NCP offers a family atmosphere, and getting to know all the family members has been enjoyable. Most memorable time/incident of your in-service training year at NCP? I can’t name just one so I will list a few. Firstly, the World of Work at DUT, where the students/in-service trainees represented NCP Alcohols. The 2019 year-end function with a casino theme was also memorable! Lastly, training operators and management on the plant operations for the NCP100 project has been a daunting yet exciting experience. Your future ambitions? To further develop my project management and coding skills in order to become a project manager. I would love to gain international experience, so before settling down, I want to structure my career to see firsthand what the world has to offer.
Introducing the Class of 2020/21 Logan Arumugan - Electrical In-service Trainee Logan joined NCP in July, having studied Electrical Power Engineering (Heavy Current) at DUT. His arrival coincided with the peak of the Covid-19 pandemic, and he was very impressed at the manner in which the pandemic was (and is) being handled at NCP. He was also impressed by how friendly everyone plant was to him. His most memorable experience to date is the July shutdown that occurred when he first arrived at NCP. Logan plans to further his studies to become a fully qualified Electrical Engineer.
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Thandazani Cele – QA In-service Trainee Thandazani joined NCP in January as a QA/QC Laboratory In-service Trainee, having obtained his National Diploma in Analytical Chemistry at MUT. The way that people communicate with and respect each other at NCP have made a big impression, as have the planning, teamwork and time management he’s seen here. During lockdown, Thandazani had to handle two sections at once and report results on time. He learnt a lot from this experience. Thandazani is looking forward to learning new skills and improving his knowledge to advance his career.
Emilio Chetty - Electrical Engineer Trainee Emilio studied Electrical Engineering (Heavy current) at DUT. Before he became part of the NCP team in September, he was nervous about working at such a large company, however, the warm welcome and levels of hospitality he received really impressed him. The projects he’s been involved in at NCP Alcohols have provided Emilio with an introduction to industrial switch gear, and motivated him to become part of the electrical industry. He plans to study and grow further in the electrical field.
Kiven Chetty – QA In-service Trainee Having studied Applied Chemistry at UKZN, Kiven began his in-service training at NCP Alcohols in 2019. His current in-service position is as a Laboratory Assistant. He says that working at NCP has been a challenging experience, but one that he has enjoyed a great deal. He appreciates the culture at NCP, while the work ethic and team standards he’s encountered have inspired him to strive to attain the same levels. Kiven is of the opinion that the future at NCP is bright, and he hopes to be a part of it.
S’bonga Dlamini – Process Instrumentation Trainee S’bonga obtained a National Diploma in Process Instrumentation at DUT, and began his in-service training at NCP in November. At first, he thought he’d never get used to this big place or be able to memorise all the plant names. When his mentor asked him to go to the Fermentation Plant, he didn’t know where it was, however, he is now familiar with the entire site. When he finishes his training at NCP, S’Bonga plans to elevate his knowledge of instrumentation, and would like to go back to university and complete his honours.
Kalvin Govender - Instrumentation In-service Trainee Kalvin began his instrumentation in-service training at NCP Alcohols in August this year. Prior to joining the NCP team, he studied Electrical Engineering at Umbilo Private Campus, and then furthered his studies at Coastal College. While his journey at NCP has only just started, Kalvin is really enjoying the working environment. He appreciates the many opportunities it affords him to gain valuable experience, through which he can grow. His immediate goal is to complete his training at NCP. Thereafter, he intends to study further.
Carl Joseph - QA In-service Trainee Carl studied analytical chemistry at DUT, and is currently a lab student. When he first arrived at NCP there was a lot to take in, but slowly everything fell into place. On first inspecting the equipment in the lab, he was happy and excited to see so many GC’s. His most memorable time at NCP was when the lockdown was implemented, and he started working from 6am to 6pm. Carl is delighted to be doing his in-service training at NCP, because both his father and grandfather worked here. He plans to complete his advanced diploma in 2021.
Sihle Mthembu - Mechanical In-service Trainee Having completed his National Diploma in Mechanical Engineering at DUT, Sihle became a member of NCP’s Engineering Department in January this year. Engineering Manager, Morgan Morefu, is his manager and mentor. To date, Sihle has worked on several projects involving the boiler house, as well as other projects at the plant. He is enjoying his in-service training so far, and is taking advantage of every learning opportunity that comes his way. In the short term, his plan is to secure a job for next year.
Hlengiwe Mlangeni – QA In-service Trainee Hlengiwe obtained a National Diploma in Analytical Chemistry at MUT, and is currently doing her in-service training at NCP as a QA/ QC Laboratory student. She enjoys the culture of support she’s encountered at NCP, and considers it to be an excellent environment in which growth and learning are encouraged She also appreciates the leaders, who communicate their vision clearly, and inspire the members of their team to reach their goals. Hlengiwe’s immediate ambition is to obtain more formal knowledge in chemistry.
Timothy Moodley – SHEQ In-service Trainee Timothy obtained an MSc in Environmental Sciences and Management at UKZN, before joining NCP in January. On first impression, NCP seemed vast and intimidating, but he quickly made friends and gained confidence. Helping the SHEQ team to protect NCP from the effects of the pandemic provided an opportunity to maximise his growth and learning. While at NCP, he’s furthered his studies in SHEQ, and is currently studying towards his NEBOSH IGC. He hopes to secure a career in SHEQ on completion of his in-service training.
Thando Sibeko – Electrical Apprentice Thando joined NCP in September, having completed his studies in Electrical Engineering (Heavy Current) at Amajuba College, New Tech Campus. He considers NCP to be an environment that offers many learning opportunities, and is looking forward to learning more. Thando finds his colleagues to be friendly, and hopes to gain experience to boost his career in the future. It is his intention to build on the skills he learns during his inservice training, and develop a clear picture of where he sees himself over several years within the company.
Shonisani Sikhwayi - Mechanical Apprentice Shonisani joined NCP in 2018, having studied mechanical fitting at Coastal TVET College. On arriving at NCP, the way that people behave towards each other and the manner in which the engineering team works together made a big impression on her. At her first year end function at the Hilton Hotel, she was shy as she was still new to the company, but her managers made her feel at home. Her immediate ambition is to become a mechanical artisan, but rather than being an artisan for good, she wants to study further to fulfil all of her dreams. LADUMA December 2020
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Engineering Efficiencies in a Tough Year When he joined NCP less than a year ago, Morgan Murefu could not have guessed what 2020 held in store. He looks back on what has been a challenging first year as Engineering Manager. What were the Engineering highlights of 2020? • We're proud that by end of October, alcohol volume produced was 20% ahead of budget. This shows great collaboration with the production team, and is testament to the amazing effort the engineering team has invested in maintaining the equipment. • The ban on the sale of potable alcohol when the lockdown was implemented in March was a big challenge. Fortunately, a new market for sanitiser opened simultaneously. The engineering team worked with other teams to fasttrack the modifications that enabled NCP to produce drummed hand sanitiser. This intervention kept us afloat during the difficult COVID months. • In July we had a two-week shutdown when several project tie-ins were done. During the same period, we successfully carried out repairs on the Boiler 3 superheater tube. Boiler 3 is the high-pressure boiler that supplies steam to the turbine for generating all the electricity used at NCP. We started with a thorough internal inspection and discovered significant superheater tube failures, which we repaired within a tight schedule. The boiler has since been running very well. We also installed a new 2 bar pressure-reducing line to make modulation of the let-down steam controllable, thus allowing for more stable operation of Boiler 3.
The Engineering team, from left to right: Morgan Murefu, Carl Freyer, Mervin Kullen, Judy Somers, Lance Ethel and Shon Roopnarain.
What lessons did your team learn from lockdown? • COVID-19 presented us with a proud moment to see how much NCP cares for its employees. Split cover was introduced for artisans, while others stayed at home on full pay. The leadership team came to site on rotation. Laptops and internet connectivity were provided to help those working from home. • When some of our colleagues contracted COVID-19, we stood with them. This brought cohesion to the team, and enabled us to recognise how much we care for each other. • The online meetings that were introduced to maintain physical distancing brought about improved levels of computer literacy, and will continue into the future. What lessons did you personally learn this year? My greatest learning is that care for each other through tough times builds long-lasting trust relationships. A wise man once said: “People don’t care how much you know, until they know how much you care”. This is true. Is your department closing for the holidays? Partially, we’ll keep a skeleton team to cover maintenance, as our plant is a 24/7 production facility.
Shon Roopnarain proudly surveys the team's efforts on the new pressure reducing line on Boiler 3
What awaits you and your team in 2021, and are you ready for challenges? Commissioning the new plant for the move to maize is our biggest challenge. Related to that, we have a big task ahead to set up the maintenance plans and establish the critical spares requirements for the new plant’s equipment. In addition, our maintenance personnel have to acquire new skills to be able to deliver maintenance on the new plant. We are definitely ready to face any challenge! What is your Christmas and New Year message for your team and colleagues at NCP?
The Engineering team pay homage to the sanitiser drumming station, which was critical in enabling NCP to operate during the lockdown
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To the Engineering team, I would like to say thank you for the warm welcome. I only joined NCP this year, but feel like I have been around for longer than that. I also want to thank all my colleagues for great performances in 2020. You really deserve a merry Christmas season together with your families. Please remember COVID is still with us, so enjoy the holidays responsibly, observing all the necessary protocols. I will be waiting for you in 2021!
NCP100 Project on Track Despite Challenges When the national lockdown was announced in March, a superb effort on the part of De Smet, SiVEST and NCP Alcohol’s project management team ensured that the critical NCP100 project was not derailed. Project Manager, Stephen Kitching, shared some of the details with Laduma. “The reality of Covid-19 and lockdown came fast for us, but ultimately turned out to be an opportunity to grow as a company and as a team", says Kitching. The project had been on course, but with the construction site in lockdown for 42 days, the roll-out date of May 2021 was in jeopardy. Added to this, the transport and installation of eight of the largest vessels was scheduled to take place during this lockdown period. The high costs, complex logistics and major site disruptions caused by this activity demanded meticulous planning months in advance, all of which had to be changed. Creative thinking, collaboration, and dogged determination finally saw abnormal travel permits being issued and the vessels being delivered to site. This culminated in a major milestone when the largest distillation column, at 42 meters tall, was lifted into position in June. Lockdown also resulted in two key players from De Smet Engineers and Contractors returning home to Belgium. “The loss of key resources in this period was a blow but we adapted and held regular meetings online”, Kitching explains. “We are a relatively small company, with about 100 employees on our premises. Post lockdown, we peaked with 530 contractors on site for the expansion. It was a learning curve to accommodate everyone, but peace and stability prevailed”.
Kitching is proud of the team that made up for time and delays and ensured that by the end of 2020, the project was back on track in terms of time and budget. He believes that all is set to ensure that the conversion to maize will begin by April/May 2021. “This would not have been possible if the team did not unite and align their priorities. We stuck to our tradition of a friendly working environment to enhance relations.” Even when working remotely became the modus operandi, the wheels never stopped, adds Kitching. “It had little impact on our excellent end results.” Kitching commends the leadership of Malcolm Hartwig and Robin Rondelle, the two lead Project Managers. “Malcolm sets a fine example of operating at the highest level with the right attitude. He listens well, stays calm and has his colleagues’ interest at heart. Robin is an extremely efficient operator with exceptional project management skills.” The two combine very well, and led the rest of the team to take responsibility, and eventually turn Covid into a non-event. Now all eyes are set on the NCP100 project startup. Countdown still needs to be closely monitored, stresses Kitching. “This year presented more growth opportunities than we could have hoped for. It was a good practice run for the unexpected, because as with any operation, the devil is in the detail”.
Congratulations to our long service awardees! Nine NCP employees celebrated a combined 160 years of service during 2020. Ranjini Madanjith and Robert Nyirenda celebrated their 5 year milestones; Shaleene Harichand and Zwe Mbele celebrated 10 years each; Nomvula Dlamini and Mzo Jama both celebrated 15 years of service; Zinhle Mqadi celebrated her 20 year milestone, and last but not least, Ashley Sathdav and Blessing Ngcobo both celebrated an incredible 40 years with NCP.
Robert Nyirenda
Shaleene Haric
hand Ashley Sathdav
Blessing Ncgobo
Zinhle Mqadi
a
am Mzo J
Ranjini Mandajith
Nomvula Dlamini
Zwe Mbhele LADUMA December 2020
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NCP Donates Hand Sanitiser to Local Organisations This year, we’ve all had to make adjustments in the way we go about our daily lives. One of the many Covid-related precautions that has come to form part of our routines is the fact that we now sanitise our hands multiple times each day. As part of its CSI commitments, NCP has been providing several organisations and schools with hand sanitiser at no cost. Recipients include TAFTA, Lakehaven, Girls & Boys Town, Greenwood Park SAPS, the SPCA (Durban Central & Amanzimtoti), Sea Cow Lake Secondary School, Kenville Primary School, Fulton School for the Deaf, and CROW. Below, representatives from some of these organisations tell us how NCP's donation has been of benefit. Mary Koen, Bequest Liaison and Fundraiser, Durban & Coast SPCA: Lockdown and the Coronavirus pandemic have changed the way we do many things at the SPCA– such as having to stay a safe distance from everyone and having to sanitise at all entrances – but one thing that never changes is the love we all have for animals. Thank you for helping with hand sanitiser, we don’t know what we would do without loyal friends and animal lovers like yourselves. Our organisation is entirely reliant on generous contributions from the public and local businesses to fund the vital work we do for animals. You’ve helped us to ensure that many animals’ lives are saved, conditions under which animals are cared for are improved, and justice is served to those that don’t adhere to the laws in place. You are making a huge difference – and we can’t thank you enough!
thus helped us to stay safe, while using our limited funds for other unforeseen expenses. We are so thankful for the generosity.
Vivinenne Shepherd and Nomcebo Lukhele with learners (back row from left) Jayden Fortuin, Qhawe Zulu and Sphesihle Hlathi, (front row from left) Nomonde Mofokeng, Amkela Zuma and Sphesihle Lekhoana
Fiona Anderson, Manager, Jona Vaughan Home: On behalf of Durban and Coastal Mental Health and the residents of Jona Vaughan Home, we would like to send you our grateful thanks for the very generous donation of 150L of sanitiser in July, followed by monthly donations of 25L each. This has been of great help in enabling us to keep our residents and staff as safe as possible during these challenging times. Your continued support is much appreciated.
Abigail Roundi (volunteer), Sally Francis (shop assistant) and Chantall Rode (marketing assistant), pictured in the SPCA charity shop with a sanitiser dispenser
Simi Sivasanker, Admin Clerk, Fulton School for the Deaf: We are a residential school for Deaf learners. The school currently has 104 learners, approximately half of whom stay in the hostel, and is run by a staff of 63. Once learners were able to return to school, the COVID-19 committee worked tirelessly to ensure that hand hygiene was possible in every area – including bathrooms, hostels, dining rooms, classrooms, offices and shared spaces such as the computer centre. The support from NCP has meant that at no time has the safety of our community been under threat, nor has our school had to fund the purchase of additional hand sanitiser to uphold our stringent hygiene standards. NCP has
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have the children on a multivitamin due to COVID-19, and they are all doing well. While this adds cost to our daily operation expenses, with the help of NCP, we have been able to minimise out overall costs drastically. Our youth on the Tongaat Campus have had access to the sanitiser, which has been used in all areas of the campus to keep everyone safe.
Wendy Gumede, Youth Care worker, sanitises children's hands at the youth care development campus
Alexandra Koegl, Communications & Marketing Officer, Centre for Rehabilitation of Wildlife (CROW): We are incredibly grateful for the generous donation of hand sanitiser made to CROW. As an animal rehabilitation centre, hygienic practices and a sterile environment are of utmost importance. Bandaging wounds, cleaning cages and going out on rescue calls involves a great deal of contact between people, animals and objects. Having an effective sanitiser on hand means we can ensure that no germs are spread as we go about our normal day. It has also been invaluable during the COVID era, giving us extra peace of mind about not contracting the virus at the workplace.
Evelyn Reid of Jona Vaughan Home sanitising residents’ hands
Lesley-Anne Moon, Service Consultant, Girls & Boys Town: Thank you very much for the generous donations of hand sanitizser from NCP. The children returned from their short break in October and are writing exams. We
CROW clinic nurses Sue-Ann Shutte (left) and Zoe Dougall sanitise their hands