December 2018
LADUMA Celebrating
150 years of distilling 1868 - 2018
Green goodwill - plants give life to all things on Mother Earth! Ace Govender takes a break from his busy schedule to help create a community vegetable garden at Tafta’s St Martin’s retirement village.
Automation tide rolls in…
Message from the MD Not many managers get the opportunity to write a message to the staff of a company that is celebrating 150 years of existence, even if it has been through Peter Starling, numerous Managing Director different forms in that time. I consider it a privilege to have been involved with NCP Alcohols for many years and am extremely proud of the achievements of the company. Distillation activities started on the banks of the Umgeni River where NCP Alcohols is now situated 150 years ago in 1868, and over time the distillation techniques became more refined, and the capacity increased ultimately resulting in NCP Alcohols as we know it today. Many, many people contributed to making NCP Alcohols the company it is today, and I hope that the company made a difference in their lives as well. It is worth taking some time to consider what it takes for a business to exist for 150 years. How many times the strategies, structures and areas of focus must have been adapted, changed, revised, how many successes must have been celebrated and how many failures treated as learning experiences, all these form part of the DNA of NCP Alcohols, supporting the one common theme throughout, the production of the highest quality alcohol. We, the current custodians, have a responsibility to continue to build on this legacy, adding our contribution. Regarding adding our contribution, we are about to commence the next major project and quite possibly the most ambitious in NCP Alcohols history. Financing and project documentation is almost complete, notifications have been submitted to the relevant authorities for approval both in South Africa and Europe and on receipt of these final approvals the project to increase capacity, improve energy efficiency and convert our raw material base will commence, most likely toward the end of Q1 next year. More information will follow in 2019, but as with all opportunities, it will bring changes, challenge and some disruption during the construction period. It will be vitally important that we continue to focus on doing the right things well, not allowing distractions to negatively impact on producing and delivering top quality alcohol to our customers. 2019 will be a big year for us, so enjoy the festive season, if you are taking some time off, relax with your families and travel safely. Thank you for your support and commitment during 2018, best wishes and happy holidays.
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LADUMA December 2018
To keep its status as a leading contributor in the international beverage & food, cosmetic and pharmaceutical arenas, NCP Alcohols is fast gearing itself towards increased automation and adopting of leading new technologies. One happy team! These days the hardworking controllers in the operation room at NCPA are smiling folks after their shifts have been adapted to introduce a new time system leading to healthier balance between work and personal time. The result is happy faces and more productive input at the plant! The team is from left to right: Zwelenkosi Mbhele, Simangele Ndlovu, Khayelihle Ntetha, Sphamandla Buthelezi, Musawenkosi Luthuli and Siphokazi Majozi.
New shifts = happiness amplified! Change can be a powerful thing... just walk around in NCP Alcohol’s operations control room where you will be met with broad smiles these days! The reason? A brand new shift system which has not only majorly improved working conditions of controllers but empowers them. Zinhle Mdadane who is the operations manager in the Production Department, confirms that the new shift system has changed a lot in a very short time. Previously the shift system made provision for four shifts: one worker was on duty in the morning, one in the afternoon, one at night and one off. “It was long hours, and the operators got tired, and continuation, including clear communication, was difficult when handing over.” It was challenging to get the best out of our shifts, and the solution came from among the operations controllers themselves as they realised that they would have to bridge the gap between handovers better to benefit the company and the shift workers, explains Zinhle. It’s all hats off to our controllers and the system now allows for two people on duty every day – one on day shift and one at night. It entails a 12-hour shift for three days at the most at any time, and then the controller is off for a few days. This has resulted in controllers more energetic and willing to perform at their best. “We literally saw changes overnight with lovely participation from everyone.” With the new system we are genuinely empowered as it also allows time for stuff like checking emails and attending meetings and to be available for training such as to use computers, says Zinhle. Can’t wipe happy off these faces…
Laduma spoke to controllers on the floor about the new shift system at NCPA. Zwe Mbhele, shift manager, reckons it is the best thing by far. “It is a good initiative which has made so many things easier for my team.” With more days off, he and his colleagues get to spend more time with their families and have a more balanced life. As the old system often resulted in fatigue he is sure the new one will cut-down on sick leave too, adds Zwe. For controller Lihle Ntetha the added time for family is right up her alley. “I can now take my daughter to school and get to rest properly at home before reporting for a shift again.
Laduma asked Shon Roopnarain, electronic/ instrument superintendent and Colin Mkhize, the instrumentation trainee technician, to divulge the more delicate details of their team’s sweet successes in 2018.
The instrumentation team completed a few projects during the year. They addressed the inaccuracy of storage tank 36 which previously used a float and counterweight as the main level indication on the tank. As the tank stores imported alcohol, high accuracy measurements is a prerequisite. It was decided to move the measuring instrument from receiver tank 21 to install it on tank 36. The bottom distillery cooling water supply is separated into two sections, the lowpressure system and the high-pressure system. Previously there was one pressure
transmitter which was on the low-pressure system feed lines but was also linked to the high-pressure system. Because these two systems were separated, a pressure transmitter was added on the high-pressure system. This was done to decouple Aerosol, Potable and the Washer column from the remaining Bottom Distillery columns so that if the low-pressure system tripped the other parts of the plant would not trip as these systems were independent. Once more smart automation techniques were applied to achieve higher plant availability. The radar level indicator of receiver 20 was moved to 19, and another one moved from receiver 25 to 21. Due to tanks being repurposed and their duties changing, a higher accuracy level measuring device was required for both tanks. This will aid in: • Quantifying alcohol production • Customs and excise compliance • Volume transfers via DCS printable Radar level transmitter principle of measurement – The high frequency electromagnetic pulses transmitted down the probe is reflected at the point of discontinuity between the air and the process medium. As with other time of flight instruments, those reflections are measured by high-speed circuitry in the transmitter, thus establishing the level measurement.
A pressure transmitter was installed to measure and monitor incoming water supply after unplanned cut-offs from the municipality. We previously had no indication of pressure changes and only relied on the breakwater tank level which did not give us a big enough time period to be able to react to water cut-offs. The new pressure transmitter installation on the incoming corporation water line is linked to an alarm to alert the team when the incoming water supply pressure low. The installation of this warning system gives us more time to assess the situation and react by changing over to fire water.
Clearly, on a roll, Shon and his team are ready for the new challenges of 2019. Some projects are planned and budgeted for next year with some in progress already. One revolves around buffer tank washings where a new system of water saving has been introduced. Instead of dumping water as in the past, it will now be reused back into the Fermentation process as start water. This will aid in: • Improve effluent quality • Save water usage
“You come to work more motivated too. Please don’t change it again,” she urges with a big smile. Simangele Ndlovu also raves about increased family time with her husband and daughters. “You can now rest properly and report to work with a fresh mind. I can see how the new system benefits us all. We are more positive and focused, and communication between us is much better.” It also binds the team and results in a better end product. Furthermore, she and her colleagues can now attend training courses like the recent one on conflict management. For Simangele safety is very important. Before any job, the environment is inspected to assess what kind of protective gear – overall, boots, gloves and earplugs – workers will be needed. Her colleague Siphamandla Buthelezi is equally ecstatic to have more time for family and to study. “It is fantastic news for my wife and kids. I was able to take them to the park to play.” Siphamandla also cites the mental health benefits with the new shifts. “You can rest and properly prepare for your shift. Oh and by the way it also saves me on petrol,” says this happy man.
ment pnarain (centre), electronic/instru Shon and his super boys! Shon Roo this time big ess succ lled team who sme superintendent, and his dedicated Mazibuko, ele San pa, Cap nda Siya left: from year! With their proud boss are ize and Andre Ramroop. Shon, Aashish Bharat, Colin Mkh
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Buffer tank pump and flow meter
Incoming water pressure switch
Installed radar
Cooling w pressure tr ater ansmitter
NCP Alcohols Sustainability Report 2017 Compliance As one of the leading providers of high-quality fermentation alcohol to both local and international markets, NCP Alcohols considers health, safety and the environment as its highest priority.
Furthermore, Logan Naicker the Logistics manager requested that temperature indication be made available for the storage tanks. This is required as temperature compensation is necessary when taking stock readings. The proposal was to install temperature pockets (thermowells) on existing takeoff/sample points and use a portable handheld temperature indicator. As tanks need to be empty before installing the temperature pockets, only 30% is completed so far. Another project will entail replacing an old mechanical scale which is B.E.R with an electronic one in the drumming operations as every drum must be weighed correctly with traceability. Also in the pipeline is automating the washing of the aerosol decanter. The results of sampling showed that although the washing is effective in reducing cyclohexane to as low as 2%m, a lot of cyclohexane settles the base by the second hour. Operators wash for varying amounts of time, and at varying frequencies. The automation of aerosol
decanter washing will remove variability introduced by operators and will allow the washing to be conducted more frequently without putting additional work load on the bottom distillery operator. The washing will also be trended on DCS, that will enable easy tracking for troubleshooting and monitoring. With the world class automation at NCPA, the DCS is the heart of all operations at NCPA. Another four receiving tanks inlet valves will be automated. The aim with this project is to: • • • •
Improve process time Improve safety for the operators Ease of operation Maintain integrity of transfer
The alcohol transfer from the receiver forms the basis for the Excise Production and it is therefore crucial that these transfers can be relied upon. Any unmeasured transfer puts NCPA at a risk of penalties. Shon confirms that instrumentation and control systems is paramount at any modern plant and that this field is evolving super-fast
and continuously. “We need to keep up with new technologies and stay competent, and be willing to learn new stuff and adapt to this ever-changing environment.” He adds the future is automation. The new 4th industrial revolution is underway. The Industrial Internet of Things (IOT), which is also known as Industry 4.0 when applied to the manufacturing industry, is a concept of integrating smart manufacturing machinery, AI-powered automation, and advanced analytics to help make every factory more efficient. “IOT 4.0” benefits include energy efficiency, predictive maintenance, higher product quality, cloud technology, reduced downtime and faster more informed decisions. “It will always be a team effort, and we have to be on our toes and have our brains sharpened to think fresh and new.” The two men have a clear message to their team and colleagues before the summer break: “Take this time to take a well-deserved rest and enjoy the holidays with family and friends”
Long Service Awards
Adhering to the frameworks of the ISO 9001, ISO 14001, SANS 10330 (HACCP), ISO 45001, as well as maintaining Kosher certification, NCP Alcohols aims to assure all its stakeholders that its products and operations comply with the most stringent laws, regulations and standards. To ensure it lives up to its own high standards as a company, regularly internal and external audits are conducted against applicable standard and legal requirements. The aim of these audits is to continually improve the level of customer satisfaction, develop existing systems and promote growth of the business.
Training NCP Alcohols prioritises the steadily increase of the awareness and skills level of its employees by conducting both internal and external training. Several benefits are achieved through these training initiatives, including satisfying legal requirements; equipping the staff with the relevant skills and knowledge for the safe operation of equipment to prevent adverse impacts that can be caused by any element in our production process, supply or in the use of our products and to bridge the skills gap within the company.
During the year of 2017, NCP Alcohols completed several SHEQ training programmes such as Fire Extinguisher, Working at Heights, SHE Representative, Recycling Awareness and Spill Kit training. NCP Alcohols’ in-service training programme offers students a year of “live training” in the fields of analytical chemistry, applied chemistry, biochemistry, biotechnology, food technology, instrumentation, microbiology, SHEQ and chemical, mechanical and electrical engineering (light - and heavy current). Over and above this, the students are given the opportunity to be actively involved in the numerous community and social upliftment programmes currently implemented by NCP Alcohols.
Communication NCP Alcohols believes in “keeping it simple” and boasts an honest and constructive culture when it comes to internal and external communication with stakeholders. The company has a strong corporate brand on all corporate communication which is governed by policy and aligned with the corporate strategic intent. Today, especially when communicating sustainability, we rely more on the old saying “a picture is worth a thousand words” and share the company’s focus and intent with more visual and compelling elements to honestly portray a commitment to sustainability. An executive committee member hosts monthly (interactive) staff meetings and gives employees access to the viability of the company. Specific formal and informal communication mediums form the critical drivers of NCP Alcohols’ positive organisational resilience when it comes to change.
Corporate Social Investment (CSI) Our CSI programmes are based on the real needs of the employees and the community members of the area in which we operate. The majority of our beneficiaries are disadvantaged communities and individuals, and the company focuses its CSI initiatives in the fields that are relevant in the South African context, namely education, health and welfare, safety and environmental conservation. Kenville Primary Feeding Scheme:
This project provides one meal per week to 60 primary school learners, who are in need, at Kenville Primary School. NCPA’s Chat & Chow canteen, chef PumeSello, makes and delivers these sandwiches herself like clockwork every Friday.
Look Good Feel Better Foundation:
The company is an annual and monthly sponsor to this worthy project that enables members of the Cosmetics Toiletries and Fragrances Association (CTFA) to present make-over workshops for female cancer patients at Durban’s Addington and Parkland hospitals.
Together they boast 260 years of working at NCP Alcohols…and these stalwarts still show no sign of taking things slow now. Bongani Nkosi (30 years), Ace Govender (30 years), Bala Padayachee (30 years), Alfred Ngema (35 years), Zeph Mhlongo (30 years), Rakesh Moona (35 years), Andre van der Westhuizen (35 years) and Gopal Sooriah (35 years) are here with Peter Starling, MD of NCPA, during a special lunch to celebrate their milestones underpinned by decades of dedicated service.
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LADUMA December 2018
NCPA spots and empowers up-and-coming talent! In-service training is annually provided for students from higher learning institutions in and around Durban. The lucky ones get a chance to experience a 12-month experiential learning experience at the company to complete their qualifications.
Fulton School for the Deaf: The
company takes part in the school’s “Sponsor-A-Child” campaign on an annual basis. The programme sponsors the transport costs of one learner for one year. LADUMA December 2018
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Sea Cow Lake Secondary School Science Classes: Weekly science
classes are presented to the Grade 12 learners of the Sea Cow Lake Secondary School by NCP Alcohols’ in-service trainee volunteers. The majority of the learners in the school are from the nearby informal settlement. The project, now entering its third year, proves to be successful and some of the learners who regularly attended the lessons showed a marked improvement in the subject.
National Sea Rescue Institute: NCP Alcohols is a silver partner of
the NSRI. The special bond was formed after the company gave the institute’s Station 5 in Durban a facelift during the 2016 Madiba Day 67 minutes initiative.
Vegetable garden for the aged: Tafta’s
St Martin’s retirement village was the beneficiary of a passionate team of volunteers from NCP Alcohols who generously created a better enabling environment for the home’s elders. Tafta have been working on accessing funding for St Martins for over a year and within a two-week period the NCP Alcohols team supported Tafta’s Inspiring Active Ageing programme by establishing a healing garden, supplying a JoJo tank, and purchasing much needed crockery, curtains and tablecloths for the elders’ meeting room. Last but not least, the engineering workshop repaired the gym equipment.
practitioner twice a week and a doctor once a week. The NCP Alcohols Clinic is also the entry point for any staff member to apply for assistance as part of the company’s Employee Assistance Programme. Apart from assistance in health and finances, the company also supports an annual Wellness Day when employees receive vital health checks including a free HIV/Aids test.
Environment
Clinic
Effluent sulphate
2017 ENVIRONMENTAL OBJECTIVES Objective 1: Reduce effluent sulphate levels to ≤250 ppm by December 2017
An onsite clinic, managed by both a clinic sister and doctor, has continually maintained the health and wellbeing of all staff members and permanent contractors at NCP Alcohols. Operational two days a week, the clinic offers all staff and contractors occupational health medicals and basic primary health care checks. A significant decrease in the number of clinic visits from 2016 to 2017 has been noted. These statistics prove that implementation of the various health programmes such as yoga and biggest loser competition have improved the health of the staff. The statistics are also proof that employees with chronic illnesses have learned to better manage their conditions. In 2016, the total number of healthcare visits stood at 692, while 2017 saw a total of 547 clinic visits.
Safety 2017 SAFETY OBJECTIVES Objective 1: To achieve zero (0) fatalities and zero (0) DIFR by January 2018. Disabling Injury Frequency Rate (DIFR 2017 – 2nd Quarter)
Diabetes SA Durban: NCP Alcohols supports the Durban branch of Diabetes SA. The support is aimed at the calendar event hampers for efforts on Valentine’s, Mother’s and Father’s Day to raise funds for diabetes education. As it is not being funded by Government, raising funds for diabetes education is difficult. The education is also aimed at non-diabetics on how to live a healthy lifestyle so not to become diabetic, while diabetics are educated on how to live a healthy lifestyle to not suffer the awful complications associated with diabetes eg heart disease, stroke, amputations, kidney failure, blindness, high blood pressure, high cholesterol, nerve damage, and sexual dysfunction.
Durban Children’s Home Christmas Party: NCPA hosted a
Christmas party at the Durban Children’s Home in December. Volunteering staff members get to hand out the gifts, partly donated by employees themselves. The company sponsors the eats and treats and the remaining gifts needed.
SAPS and Community Policing Forum: A one-man wooden guard hut was donated to the Greenwood Park Community Police Forum’s CPF initiative of visible policing in the Effingham area. The area is in close proximity of the plant and in desperate need for visible policing. The guard hut will provide shelter for community policing forum volunteers. As a result of the continued support by NCPA to the Greenwood Park Police station, senior operations and safety personnel at NCPA have been offered special communications in the event of an emergency with the SAPS. Athletics Club: The company has an
athletics club managed by employees called the Leafy Leapers. Members of the club are supported by NCPA and employees can register and attend four sponsored races per year.
Soccer Club: NCP United Football Club ensures that employees are able to take part in the popular game of soccer.
Employee Assistance Programme (NCPA EAP): The company provides
the services of an occupational health
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In the year 2017 the Occupational Risks and Exposure Profile (OREP) document was released. Created in partnership with our clinic doctor and sister, the OREP details all the risks associated with each job category at NCP Alcohols. It allows the clinic staff to tailor-made conducted medicals for each individual’s job.
Hazard Identification And Risk Assessments
Objective 3:
Objective 2: To reduce the number of incidents involving hazardous chemical substances by 50% from June 2017 to June 2018.
Actions such as job observations, audits (internal and external) and general inspections take place on a regular basis. To reduce risks, NCP Alcohols has adopted and adhered to the following hierarchy of control: elimination, substitution, engineering, administration and PPE.
Improvement Opportunity (IO) System
Water: Reduce site water usage by 15% from 2016 usage. Initiatives to reduce water usage onsite is ongoing. Energy: Maintain site power at ≤2.45 MW/h. Objective was achieved.
Incidents involving HCS 2016 vs 2017
Health
Objective 3: To reduce the number of first aid cases by 50% from June 2017 to, June 2018.
At NCP Alcohols we are passionate about living a healthy lifestyle and recognise the impact that health issues such as hypertension, heart disease, diabetes, smoking, obesity, alcohol and drug abuse on effect the well-being of our employees. Our Employee Assistance Programme (EAP) and onsite clinic with trained occupational health practitioners assist employees in preventing serious diseases and effectively managing chronic conditions so that we can have a positive impact on our employees’ quality of life and our bottom line.
By regarding the health and safety of everyone onsite with the highest importance at all times, NCP Alcohols makes use of risk assessments and hazard identification actions to form the basis of the company’s Safety, Health, Environmental and Food Safety (SHE & FS) integrated management system. Before conducting any work onsite, staff and contractors are obligated to perform risk assessments to highlight the potential dangers associated with each job or task.
Objective 2: Land: Reduce general waste and increase recycle waste by 1% - December 2018. Initiatives to reduce waste on site are ongoing. Air: Maintain air emissions to below legal specification by 2017. Objective was achieved.
South African Guide-Dogs Association: The company donated
prizes towards a fundraiser held at Morningside Country Club on 1 May 2017 to assist in raising much needed funds for SA Guide-Dogs Association for the Blind.
Reduce stormwater contamination to achieve stormwater discharge specifications by December 2017. Initiatives to achieve stormwater compliance are ongoing.
First aid cases 2016 vs 2017
Ongoing awareness campaigns are scheduled to communicate relevant health issues to our staff. The results from our annual wellness day checks are used to gauge the overall health and wellbeing of our team with the aim of providing the necessary guidance and support. Our Occupational Health Programme is based on routine health risk assessments that are done by approved inspection authorities. Some of our risks include exposure to
At NCP Alcohols all safety, environmental, health, quality, security and property damage incidents are reported on our IO system. This system plays a vital role in recording, monitoring and preventing incidents which occur on our site. Every employee has access to the IO system, which creates awareness of the various events which occur on site. When an IO is submitted into the system, an investigation of the incident is required. A study requires the incident findings to be stated, the root cause of the problem and preventative measures to avoid the event from re-occurring in the future. LADUMA December 2018
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noise and hazardous chemical substances. Should abnormalities be raised from medical evaluations, then the necessary investigation and reporting will follow. NCPA employees manage their Soccer and Athletics Clubs with the support from the company. The NCP Alcohols Football Club was established in 2009 and hosts friendly matches at least every quarter. The company’s athletics club, the Leafy Leapers, is affiliated to the KwaZuluNatal Athletics Federation and employee members are sponsored for their participation in four events per year.
HEALTH OBJECTIVE 2018 Objective 1: To achieve zero (0) NIHL cases for 2017. Objective was achieved.
Energy And Carbon Footprint
2017. Initiatives to reduce waste onsite are ongoing. Water pollution: All spillages must be reported so that we can prevent water pollution. It is imperative that any spillage is minimised or timeously cleaned up appropriately.
2017 WATER POLLUTION OBJECTIVE Objective 1: Reduce site water usage by 15% from 2016 usage. Initiatives to reduce water usage onsite are ongoing. Air pollution: We have changed from coal boilers and now utilise gas boilers in our plant. CO² gas from our fermentation plant is sold to a gas company and is eventually used in the beverage industry.
2017 AIR POLLUTION OBJECTIVE Objective 1: Maintain air emissions to below legal specification by 2017. Objective was achieved.
Preservation Of Resources Resources such as water and electricity need to be carefully maintained, and at NCP Alcohols we pride ourselves in adhering to suitable methods of sustainability and limiting resource wastage.
• During the first stage of the fermentation process, acid condensate is used to dilute the molasses; the water which is used in this process is recycled water which is obtained from the distillation process and the buffer tank.
According to him, the metro’s fire department came out in full force for the drill. As part of it, a fire scenario was staged, and a man with a broken leg was trapped on the first floor in the old distillation unit.
• Molasses is one of our key ingredients in manufacturing our product, and this ingredient is a by-product from local sugar refinery’s which is recycled into making ethanol.
• In our process, vapours which are produced during the evaporation process are used to heat the next evaporator, this reduces the amount of steam used. • On our plant lagging is used to prevent heat loss to the environment, this reduces our heat emissions.
As a leading producer of chemical products for use in the international beverage and food, cosmetic and pharmaceutical markets, NCP Alcohols has an emergency strategy in place befitting a highly hazardous business. Laduma spoke to Kelvin about the recent joint emergency evacuation exercise held with the eThekwini Metropolitan Municipality at the plant.
Some of the conserving strategies used in our process include:
• Concentrated molasses solids is a by-product from our process. This material is not discarded but instead sold to local farmers and is used as feed and fertiliser.
‘No room for error at plant.’ Kelvin Timm, SHEQ officer at NCPA, is tasked to keep all emergency plans at the plant fine-tuned and ready 24/7.
NCP Alcohols is committed to reducing and eradicating harmful environmental factors. Therefore, we strive to ensure that our manufacturing process is as sustainable as possible.
• CO2 is a by-product obtained from the fermentation process, this gas is then captured and sold, which reduces our impact on global warming.
any emergency Kelvin Timm is your go-to-guy in ert keeps a exp d one seas The at the plant. safety. He with do watchful eye on everything to h can act whic team fire his of d is notably prou rgency. eme an of within a few minutes in case
Procurement And Supply Chain At NCP Alcohols we seek to ensure that all of our raw products, which are acquired for the production of our ethanol, are procured from suppliers who are both sustainable and environmentally responsible. Also, NCP Alcohols disposes of waste through certified and accredited recycling/disposal suppliers which are regularly evaluated.
“We were able to bring him safely down to the ground in just 5 minutes. He was taken to the western yard and stabilised before the metro’s ambulance picked him up.” Kelvin is full of praise for the metro’s participation and the longstanding good relations NCPA enjoys with the fire department. “I have learned a lot from these guys who are experts in the handling of emergency operations and also have been involved in safety audits at our plant.”
In turn, the municipal department has over the years invited Kelvin to join them for emergency operations at airports and hospitals in the area. He cites Ivan Pillay, chief of fire safety, and Derick Moonsamy who have extreme knowledge of fire safety. “I used to be a boilermaker and welder, and the combination of experiences ensures our safety plans in the wider community stay relevant. Kelvin stresses that safety at a major hazardous installation such as NCPA is vital. “There is, simply, no rule for error.” It is critical that his team is ready to act within a few minutes. The staff practice weekly to ensure that they are able to evacuate the entire plant is just 3 minutes. Alarm drills are held every Monday and Friday. On Mondays, the evacuation alarm – a straight blast - goes off when personnel must evacuate their workstations immediately and meet at the outside emergency assembly area at the old distillery.
On Fridays, it is the turn of the gas alarm when a wave-like siren indicates gas emission at the plant, also for our neighbours. In this case, the staff has to stay inside the buildings. “That is the only two days when the sirens are used as a false alarm for drills. In any other case, the sound of an alarm will indicate a real-life emergency.” Kelvin is also responsible for healthy gas levels at the plant. Although every section does its own testing, Kelvin will clip on his equipment regularly and walk the entire plant to ensure that standards are within required limits. Due to explosive and highly flammable products been used and produced on site, extreme precautions are needed. Every vessel entering the plant will be washed, flushed, ventilated and tested for gas levels before leaving. NCPA does not take any chances with safety, confirms Kelvin.
• To reduce environmental incidents such as spillages, we have implemented bunds on our plant.
Pollution Land pollution No littering is allowed onsite, and waste bins are provided in all areas of the plant. Specially marked containers are provided for the recycling of cans and paper. Cardboard is also collected for recycling. Process areas around the plant are bunded for the containment of spillages for recovery. All process effluent is directed to the effluent treatment plant, and after that it is directed into the municipal sewer system, allowing for limited pollutants to be transferred.
2017 LAND POLLUTION OBJECTIVES Objective 1: Reduce general waste and increase recycle waste by 1% by December
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Health Clinic This qualified nurse is running the occupational health clinic at NCP Alcohols. When Laduma visited the clinic, Ashnie Nair (left) and Lulu Mokoatle were busy to inspect the first-aid boxes. This task is performed monthly to ensure that in case Ashnie is not available the minimum requirements are met and available in case of an emergency at the plant. The good news is that clinic visits have decreased in 2018; she shares with a big smile. “Furthermore, all the 2018 goals have been met, medicals were performed in time, and we’re already drafting a new roster for next year’s medicals,” she added. LADUMA December 2018
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Kick-start set Aashish on the way!
The all-time low spill is actually all-time high! The Production Department is passionately driving the company’s no waste spillage goal and the team’s hard work and dedication towards lower levels of toxic effluent sulphates recently came together when NCPA set a new record with levels hitting an all-time low of 158 ppm in October. This is not only the best figure for this year but also the lowest ever achieved at the plant. Siphokazi Majozi, assistant production manager explains the target was 250 ppm, so achieving a much lower level of 158 ppm was a sweet success after a non-stop two-year push to get everyone on board.
how to dispose of waste properly.
“We may live in a superfast millennium but changing people’s mind-set takes time and patience. There is no quick fix - a breakthrough can take years.”
She is also full of praise for the culture of teamwork at NCPA. “It stays an amazing experience when we get together, sit down as a team and find solutions for every problem. To then see progress and changes towards achieving these goals keeps me happy.”
This came into focus with the challenge of effluent or wastewater at NCPA. As a component, sulphates enter the plant through the using of molasses. It is toxic to nature producing acidic H2S, and legal amounts have to be discharged. “Effluent is controlled by strict laws and has to be monitored very carefully. We must comply with the EThekwini Municipality,” confirms Siphokazi.
Happy! Sihle Dlamini, Nomsa okazi Mabaso, Nathi Zikhali and Siph the r afte up bs thum the give Majozi company’s no waste spillage goal reaches an all-time high!
She adds that it was a slow, sometimes even “challenging” process over two years to change a culture and mind-set about waste water. Initially, effluent was seen as waste that had to be washed merely down. “We had to unlearn and change our beliefs on how to handle the stuff to dispose of it correctly.” The buy-in of all parties was vital which explains her happiness when she sees people walking with containers knowing
The record-breaking was the result of working hard towards this lofty goal, states Siphokazi. “It was a constant drive of going from every level.”
Siphokazi acknowledges that any change is hard and is therefore not shy to comment her team with this year’s successes. “It is difficult to embrace changes when a company wants to transform into a new direction. Communication is key.” As a dedicated runner with a healthy mind and body, she is stocked-up well with energy for 2019. She urges colleagues to keep on doing what must be done and then celebrate achievements before taking on new ones. Students at NCPA must also stay excited and keep on learning. “We try to expose them on a wide front at NCPA and know they will be able to apply them well wherever their career paths lead to.” But first, she will, as the rest of the staff at NCPA, take time off to rest and enjoy lovedones and to reflect on this year and 2019.
On track to a paperless workspace As a modern company which is regularly awarded globally for its products, NCP Alcohols strives to uphold the highest international working standards. Lorraine Mudaly, SHEQ (safety, health, environment and quality) systems manager at NCPA, is the wise woman behind the Integrated Management System (IMS). When Laduma spoke to Lorraine, she had reason to be happy as NCPA has successfully transitioned their Integrated Management System to the more recent versions of the ISO 9001 and 14001 standards and are one of the first companies to migrate to the new ISO 45001 standard which was launched by the International Organization for Standardisation (ISO) earlier this year. Lorraine explains that the ISO 9001 standard spells out the requirements for quality management in the workplace with a focus on customers. This standard
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provides a framework for meeting and exceeding customer expectations. “Let’s face it, without any customers you don’t have a business!” NCPA has always been passionate about meeting and exceeding its customer requirements and continue to strive to grow with our customers using ISO 9001 as a competitive tool. From a duty and care point of view, NCPA does not want to impact negatively on the environment while producing our products, adds Lorraine. The ISO 14001 system helps us to identify and manage aspects that could impact on the environment and at the same time reduces our risks of legal noncompliance. ISO 45001 is a standard addressing
occupational health and safety management systems. It was previously a British standard known as OSHAS 18001 but has since been adopted by ISO as an international standard that can be integrated with all other ISO standards. “This system deals with the people in the organization and focuses on the health of workers physically, mentally and emotionally. It puts standards in place so that workers’ stay safe while executing their duties and that their health is protected at all times.” According to Lorraine NCPA has run an integrated management system since 2010. Integration of the various ISO standards allows for efficient implementation of the standard requirements, for example, NCPA
Instruments and Electronics in his hometown of Stanger. An advertisement on the company’s online career portal about an apprenticeship vacancy at NCPA caught his eye, and he applied.
One of the trainees at NCPA in action! Aashish Bharat, who completed his practical training at the company, performs a diagnostics using a field communicator on a level transmitter which measures the level of a fermenter.
To give youngsters a break and opportunity at the start of their careers is very much part of the worker-friendly policy of NCP Alcohols which echoes strongly in extraordinary low staff turnover. Aashish Bharat (21) is an excellent case in point. He is the youngest apprentice to complete his apprenticeship at the Durbanbased company. Aashish was only 18 when he started with his apprenticeship at NCPA three years ago. After finishing matric at Glenhills Secondary, this ambitious youngster obtained his N courses in Industrial
has a single internal audit programme that incorporates the requirements on all the ISO standards that the company currently subscribes to. Although we currently have both hard copy and electronic documentation, most IMS documents are saved and stored electronically since NCPA is supporting and aiming at becoming a paperless business which supports our initiative on becoming environmentally sound. From a safety perspective, Lorraine encourages all employees to always be vigilant. “We can’t afford to drop our guard, especially this time of year as people are normally more tired and can become more complacent.” At the same time, this time of year is peak period for NCPA, as customers are stocking up for the holidays. “So, it is a demanding period, and employees need to always be aware of risks involved while performing their duties.” Lorraine confirms the most significant challenge and focus for the SHEQ team in
His application was successful, and he became part of the team in the Instrumentation Technical Department where he assists in the maintenance of instrumentation on site to ensure reliable plant operation under the mentorship of Instrument Technicians. “It is a great on-the-job learning experience. Working for NCPA is a privilege as it is a top company whose global quality achievements speaks for itself.” Aashish will be forever grateful for this golden opportunity and mentions his supervisor Shon Roopnarain and currently retired Instrument Technician Ronnie Wobben as excellent senior mentors from whom he has learned a great deal. “I arrived at NCPA with only theoretical knowledge and very little hand-skills.” He is equally complimentary of the team he is part of, consisting of Andre Ramroop, Sanele Mazibuko, Colin Mkhize and Siya Cappa. “Our team is awesome and great to work with. At the same time, they are also good mentors to me, and I keep on learning. What I know at present, I owe to them.” This happy chappy is so content with his employer that he won’t change one thing if he can take the hot seat of Peter Starling,
the new year will be NCPA’s conversion to maize project. “We must be ready and provide support to ensure that this major project running over the next two years is implemented successfully.” She is also excited about other upcoming projects and supports NCPA’s philosophy of not working harder but smarter. Lorraine also has a festive message to her colleagues: Be safe and don’t drink and drive. “But we must also enjoy the people around us.
MD of NCP Alcohols, for only one day but would like to add something. “I would like to introduce an extended training program for recently qualified artisans and technicians which the company has invested in so that they can get the feel of a higher level of responsibility.” “NCPA is a top-notch business and place to work for. The way employees are treated here, and the camaraderie among colleagues are special.” Now that he is qualified as an artisan, he can tick off the first of his career goals. Next on the list is to further his studies in the engineering field, specialising in computer systems engineering. He will study part-time at the Durban University of Technology and keep on working. “It’s a winwin situation,” remarks Aashish. His message to fellow young adults and students is to understand that there is no substitute for hard work and the fruits it will bear. He openly talks from firsthand experience. Just the fact that he got a lucky break and can do what he loves and wants to as work gets him out of bed every morning and on time at his workstation. And every day is different with a new set of challenges, states Aashish. He adds it is also vital to keep up-to-date and be on par with the fast progress rate in the 21st century, notably in technology in our line of work. Laduma congratulates Aashish and wish him the best for the bright future he envisages!
Sometimes we easily neglect our loved-ones.” Like all other career women, Lorraine sometimes struggles to balance work and her private life. As a wife and mom, she has to keep her priorities in check. She believes a healthy lifestyle with a good diet and regular exercise is equally vital to keep functioning at the highest levels. As she is passionate about her work and career, time allocation, also for fun, is her most significant friend.
with SGS raine Mudaly from NCP Alcohols World-class business we are! Lor andt to Niem rie Ger and der Ton etha van k’ of auditors Leon Govender (left), Sar pac the in der ‘lea ded NCPA for being a 01. her right. The audit trio commen 450 ISO as wn kno d dar stan al tion companies migrating to the interna LADUMA December 2018
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When opportunity knocks at the door... Sometimes you can flex your muscles in unexpected ways. This was true for NCPAlcohols when a new client with specific requirements was added on the customer database in 2018. According to Elaine Wilson, marketing and distribution manager at NCPA, the hunt was on for an additional customer for anhydrous alcohol. “The Marketing and Sales team brought the new local customer on board, and NCPA started to supply in the last quarter of the year. We recognised this client’s requirements presented new challenges to us, and the relevant teams raised their hands.” The product presented specific challenges for Site Logistics. Two unique blends had to be created for this customer. It is, however, not possible to simply blending this product and loading it into bulk road tankers for delivery. Each blend requires accurate measurement of the denaturant to be added to the anhydrous alcohol - if the quantity is incorrect the final product could be offspec. This would result in removing some of the product from the bulk tanker and top
The projects and site logistic teams came up with a solution by installing piping that runs directly into the loading gantry - the amount of denaturant is measured on a scale close to this gantry and then pumped via an airpump into the tanker simultaneous with the alcohol.
it up with either denaturant or anhydrous alcohol. An off-spec product would also have resulted in huge time, handling and product wastage and eventually financial loss adds Elaine. It is vital that the whole process is continuously analysed to ensure that the final product meets specification. This takes quite a bit of time and would have resulted in many hours to make the blend.
Even with all the initial challenges faced, Site Logistics together with the Distribution team have performed admirably in meeting and exceeding the customer expectation with regards to quality and on-time delivery, states Elaine.
Due to splendid teamwork, final design and methodology for handling this product they are able to reduce the blending time dramatically.
She is especially proud of this achievement as it also ensured that the product reached the client in time for their peak season demand during October and November.
“The initial blends used a flow measurement system that turned out to be incompatible with the alcohol and denaturants solvent properties and another plan was needed to achieve our objective,” explains Elaine.
Elaine beams about the new customer’s happiness with the end product. “It is all made possible by an enthusiastic team effort to let NCPA shine.”
e! This group A happy customer lets NCPA shin ectations exp r ome cust eded exce es of colleagu vation inno and k wor with their excellent team t. clien new a from est requ ial spec during a
Happy 150th Birthday to NCP Alcohols 53 MM
65 MM
ek n the Ancient Gre 150 years ago, whe ed the area underhed blis “river horse” roam illery was estaer. dist a s tree To fig t gian Umgeni Riv st and on the banks of the beauty of the beaals of commemoratenethe ent in the ann NCP that milesto mom d distiller wne reno internationally unique, limited edition, Alcohols, thisus Gin has been proudly Hippopotam sip you take celebrates produced. Every have been part of our the many who ney, every sip you 150-year jour e who will form anticipate is forofthos part our future.
(1868 - 2018)
A limited edition craft gin, named Hippopotamus Gin is part of the celebrations in honour of the company’s rich 150-year history! The name hippopotamus is the brainchild of MD, Peter Starling’s daughter, Lindsay Starling. She coined the name after learning more about the Ancient Greek ‘river horse’ who roamed the area under giant fig trees 150 years ago where the original distillery was established on the banks of the Umgeni River. To commemorate the beauty of the beast and that milestone moment in the annals of internationally renowned distiller NCP Alcohols, this unique, limited edition, Hippopotamus Gin, has been proudly produced as a gift to employees and customers. ‘The gin is delicious, the Boss confirms. “Every sip you take celebrates the many that have been part of our 150-year journey; every sip you anticipate is for those who will form part of our future.’ Happy toasting all!
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