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Establishing a permanent Ready-To-Drink (RTD) manufacturing plant

Turnkey project management and delivery support to establish a manufacturing plant using a ‘plug and play’ modular approach to meet the tight timescales of a multinational beverage company

Increase in demand triggers need to establish new high capacity plant

A multinational alcoholic beverages company and one of the major global producers of beers with facilities in 6 continents was experiencing increased demand. Specifically demand was soaring for premium spirits and 5% ABV (alcohol by volume) ready-to-drink (RTD) flavoured alcoholic beverages across sub-Saharan Africa. As a result, the company decided to establish a permanent manufacturing facility in Mozambique. It faced the challenge of establishing a full-sized RTD plant that would be fully operational within months to meet the potential demands.

Using a creative modular approach to accelerate installation of the plant

Malone Group was engaged by the company to deliver a turnkey project to establish a full-size, permanent RTD alcoholic beverage plant. The scope of work involved developing feasibility studies, process design (including functional specification and systems architecture), the procurement of all principal process equipment from best-of-breed suppliers and full responsibility for the installation, commissioning and verification phases.

We worked collaboratively with the customer to devise a solution that would transform the site of a former beverage importing company into one of Mozambique’s most modern beverage plants. In order to deliver the project on time, it was vital to avoid potential logistical issues associated with bringing together components from various manufacturers. We recommended the use of a ‘plug and play’ modular approach to building the entire facility using a readily assembled plant; an idea well received by the customer. This would fast track the deployment of the plant, capable of producing up to 20,000 litres of 5% ABV flavoured beverages every 24 hours.

To ensure the best plant equipment was installed, we reviewed pre-assembled plants from 10 specialist suppliers before settling on one. Some of the key selection criteria included the capability to increase capacity to match a potential increase in demand and the efficient use of utility and energy by the plant equipment. Another important factor was the supplier’s presence in the African continent for service facilitation to manage on-going maintenance requirements.

During the installation, all aspects of the project delivery were checked against the customer’s engineering excellence standards including zero harm and zero defect policies. We also ensured compliance with ATEX standards when installing the plant. The modular approach adopted by Malone Group delivered significant benefits for the customer including, tight control of manufacturing quality, reduced risk of on-site accidents due to reduced site activity, and cost reduction in installation and management processes.

Malone Group’s role as project delivery partner also encompassed recruitment and management of the key sub-contractor base for the installation and commissioning phases. We recruited from the local qualified workforce for the installation phase.

Delivering a fully operational plant in time to meet the festive demands

The project was delivered in time for the plant to start production and satisfy demands of the festive market, and meet the targets set by the customer. At the installation phase, it was found that the number of local qualified trades people was less than originally expected to join and there was a gap. We had already developed contingency plans with the company and were able to provide additional contractors from the UK to supplement the local workforce. This ensured timely delivery of the project, which was greatly valued by the customer.