In April 2017, Unilever opened Indonsa, the company’s largest ever food manufacturing facility in Durban, South Africa. The monumental plant features many “green” enhancements to reduce energy consumption – and PENETRON crystalline technology to reduce the permeability of its concrete structures.
Located on the shores of the Umgeni River (or Mgeni River) in the Riverhouse Valley of KwaZulu-Natal, South Africa, the Unilever plant was named Indonsa (“Morning Star” in Zulu). The US$81.8 million project was one of the largest private investments in South Africa since the 2010 FIFA World Cup, which also included a number of PENETRON projects.
Covering over 22,000 m² (236,806 ft²) on a 78,000 m² (839,585 ft²) site, Indonsa is the company’s largest dry foods manufacturing site in the world. With a production capacity of 65,000-100,000 tons (130-200 million pounds) per year, the Indonsa plant produces dry food products for a number of Unilever brands: Knorr, Robertson’s, Knorrox, Aromat and Rajah.
Designed with environmentally compatible features to create a sustainable manufacturing site, the Indonsa plant alone helps Unilever reduce CO2 emissions from manufacturing and logistics by about 5% a year. The company’s target is to reduce CO2 emissions by more than 40% by 2020 (from 1995 levels). For example, the plant captures rainwater from its roofs for storage in concrete tanks (1.5 million-liter capacity) and treats it for use in the plant. All water in the plant is recycled, with about 70% reused.
“The Indonsa plant is located right next to the Umgeni River in Durban, which meant a relatively high groundwater table at the construction site,” says Clive Leader, Managing Director of PENETRON South Africa. “The PENETRON team provided a practical solution that ensures a durable – and dry – structure for the dry foods plant.”
The location adjacent to the Umgeni River and a high water table presented challenges, but the dimensions of the Indonsa manufacturing plant also posed a high contamination risk. PENETRON ADMIX was employed to treat the concrete used in the foundation slab and the overflow water storage tank. Construction joints were permanently sealed with 240 m (263 yards) of PENEBAR SW-55 waterstop.
“In addition to enhanced durability and waterproofing, PENETRON’s crystalline technology also delivers long-term benefits by substantially reducing the resources and energy needed for maintenance – contributing to Indonsa’s sustainable profile,” adds Robert Revera, CEO of PENETRON International.
Durable in Durban: The aerial shot of the Indonsa plant basement shows a dry structure despite the high groundwater table from the adjacent Umgeni River – thanks to PENETRON crystalline technology.
