DÖHLER South Africa approached Sirius Engineering in 2021 to create a long-term expansion strategy that would cater to the South African market as well as potential African markets. In order to prepare for expansion, we first developed a capacity model for both the new and existing facilities using a 10-year growth forecast.
The capacity model outputs were used to create a long term Master Plan and the execution was broken down into phases. In 2022 we were appointed to carrying out the first phase of the project including our full engineering package for Project Management, Project Engineering, and Project Administration. The project resulted in a completely automated processing plant with 1,250 installed valves, 750 of which were automated through the use of ASI-Bus technology. Additionally, the system contains 500 IO-Link enabled instruments for tracking process parameters, utility usage, stock levels, and more. Over the course of the project, 8 km of pipe was installed according to a full 3D modelled process installation. The final building size was 5,900 square meters and included a cold room for the storage of raw material in tank farms, a fire store for the storage of flammable materials and a hygienic processing facility. Also included in the building was an office building that allowed for management offices, production offices, canteen, locker rooms, sanitation lobby, a micro lab and a quality lab.
The project was successfully handed over to the client in 2024 and the planning for phase 2 was commenced.
