Case study: AMKA Products (SSO)

AMKA Products manufactures more than 400 products that include shampoos, lotions, skin creams, hair relaxers, bubble baths, cleaning chemicals and dishwashing liquids. Products are distributed throughout South Africa, as well as to 34 other countries in Africa. The company employs more than a 1000 people. Currently four manufacturing facilities exist with a new facility commissioned.

Its Sunderland Ridge, Centurion, facility was the Candidate Plant for a Steam System Assessment.

The factory manufactures hair care and personal care products, comprises a blending facility and several high-speed packaging lines. This site employs 500 people.

AMKA Products operates in a competitive market where cost leadership is key to market share. Energy efficiency in the steam area was seen as an opportunity to reduce these costs and mitigate the company’s emissions. Participation in the Industrial Energy Efficiency (IEE) Project was considered a way to access expert support.

Three AMKA employees attended the Advanced Steam Systems Optimisation training through the IEE Project: an Industrial Engineer, the Environmental and ISO Systems Manager, and a Projects Technician.

KEY FINDINGS
During 2014, eight projects were undertaken, resulting in a total energy saving of 1 261 827 kWh, valued at R1 260 181. With a total investment of R437 000, the estimated average payback period was less than four months. A reduction of 330 tonnes CO2 was achieved.

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