Fuchs Lubricants South Africa officially introduced customers to its newly expanded Isando facility during a customer day last month. The event showcased significant electrical and automation upgrades that will interest contractors working in industrial automation and power systems.
Manufacturing executive Thami Mzolo, who has been involved with the project since joining the company in early 2024, comments that it is the most efficient plant built and upgrade he has ever been involved with.
“We contracted out the EPCM project to DRA Global and they did a fantastic job in terms of attention to detail on the design and execution, to the extent that we commissioned the plant a full month ahead of schedule. Since commissioning, we have achieved a 100% right first-time manufacturing result in the new plant.”
Fuchs embarked on the second round of its investment strategy, ‘Creating Capacity’, in mid-2020, explains MD Paul Deppe. “We purchased neighbouring land and as Phase 1 of the project we built a new warehouse and head office in Isando, both completed at the end of 2022. The new warehouse is 4.5 times larger than the old one, significantly reducing congestion and improving storage for raw materials, packaging, and finished goods,” says Deppe.
“The aim of the customer day was to showcase our new facilities and increased capacity. As the leading independent lubricants manufacturer, this will unlock significant further opportunities and markets for us,” comments Deppe. “It was not just the actual technology we showcased, but also the level of control, automation, and integration with our new SAP ERP system.”
Now that the expanded facility is up and running, Mzolo’s mission is to maintain flexibility while taking advantage of the high efficiencies and ensure Fuchs’ commitment to their customers of a quick turnaround. “The focus now is to look at further operational efficiencies in our processes to unlock more capacity and enhance our flexibility by removing inefficiency and waste,” says Mzolo.
The aim of the project was to move the high-volume, fast-moving, large-batch products out of the existing plant. State of the art technology has been incorporated into the new tank farm, blending plant, and filling lines, while the existing plant remains.
Mzolo highlights key advancements in FUCHS’ new production facility. The new plant has increased available manufacturing capacity by over 40%. “This means that we are geared to capture future business seamlessly and are prepared to grow with our customers.” The new plant consists of three blending vessels, five base oil tanks, and two additive vessels, adding an extra 300,000 litres of blending capacity.