With a growing demand for premium spirits and 5% ABV ready-to-drink (RTD) flavoured alcoholic beverages across sub-Saharan Africa, in late 2013 Diageo took the decision to establish manufacturing facilities in Maputo, Mozambique. Our brief was to create a full-size permanent RTD alcoholic beverage plant in just a matter of months – a facility capable of producing up to 20,000 litres of 5% ABV flavoured beverages every 24 hours and able to satisfy the considerable sales opportunities for products such as Smirnoff Spin.
To avoid the potential logistical issues associated with bringing together separate components from a multitude of manufacturers on the Maputo site, we decided to build the entire facility using ready assembled plant and embracing a modular ‘plug and play’ format. This involved selecting tried and tested pre-assembled plant from 10 specialist suppliers and ensuring precise interconnectivity between each of the separately outsourced components before they were shipped.
Our scope of works included: feasibility studies, all process design (including functional specification and systems architecture), the procurement of all principal process equipment from carefully vetted suppliers, the recruitment and management of the key sub-contractor base, as well as taking full responsibility for the installation, commissioning and testing phases.
Calling on our considerable knowledge of the supply market, all whilst paying strict attention to environmental impact, reliability, ease of maintenance and future proofing, the modular process technologies we specified included: 50,000-litre High-Strength Alcohol System; 6,000-litre/hour Premix System; 20,000 litre/hour Sugar Dissolving System; Blend Tanks; Blending Carbonation Chilling System; Bottling Tank; Water Intake, Treatment and Storage; Cleaning in Place (CIP); CO2, Glycol and Compressed Air Systems; De-aeration, Reverse Osmosis, and Alcohol Filtration. ProLeit’s brewmaxx V9 compact was the preferred software platform. Diageo selected Enterprise Tondelli to provide a complete solution for the packaging plant.
All aspects of the project were regularly checked against the uncompromising standards of Diageo’s Engineering Excellence system – an industry leading management procedure developed to reduce cost, lessen Diageo’s carbon footprint and improve both quality and efficiencies. Our own well-established processes and procedures were used to ensure safe design and compliance with ATEX directives, project accuracy and, above all, employee safety. All functional specifications were also checked against the ‘FMA Standard’ – a protocol of excellence that we have developed over several years.
Process refinement and optimisation trials were completed in January 2015 to enable full production of 5% ABV beverages such as Smirnoff Spin. This followed initial production, which was completed in time to satisfy the demands of the 2014 Christmas RTD beverages market. As an indication of the attention to detail that went into ensuring success, the second batch trials were of saleable quality, enabling the system to be immediately put into full-scale commercial scale production.
The full story ‘Out-of-the-box thinking: A new ready-to-drink plant for Diageo in Mozambique’ can be read in the April 2015 edition of Brewer & Distiller International.