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 in the Riverhouse Valley of KwaZulu-Natal, 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.
Covering over 22,000 m² on a 78,000-m² site, Indonsa is the company’s largest dry foods manufacturing site in the world. With a production capacity of 65,000-100,000 tons 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).
“The Indonsa plant is located right next to the Umgeni River in Durban, which means a relatively high groundwater table at the construction site,” says Clive Leader, MD 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 metres 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 – greatly contributing to Indonsa’s sustainable profile,” adds Robert Revera, President and CEO of The PENETRON Group.
The PENETRON Group is a leading manufacturer of specialty construction products for concrete waterproofing, concrete repairs and floor preparation systems. The Group operates through a global network, offering support to the design and construction community.
