Albany Bakeries (Albany) is proud to announce the launch of R350 million investment into a new bakery in Bellville.
The investment includes the building of a brand-new plant with new technology equipment that reduces the carbon footprint and the upgrade of interiors of the existing plan. Albany Bakeries in Bellville was established in 1970 as a venture between Tiger Oats and National Milling.
The new building occupies 6 884 square metres compared to an area of 3 766 square metres in the old bakery. The total yard size is 16190 square meters and includes new roads for delivery and commercial vehicles.
“For the upgrade, we took the environment into account and have increased our emissions efficiency by reducing the factory’s energy consumption and also placed emphasis on improving safety measures,” says Albany managing director Matshela Seshibe.
Two Tweedy™ mixers, backed by British technology, add to the output capacity from 6 000 loaves per hour to 12 000 lph, “effectively doubling the output we were able to achieve before,” says Seshibe.
Willem Marais, Albany Bakeries’ supply chain executive, explains: “With measured proportions of flour, water and yeast, the machine turns 300 kg of bread dough per batch in six-minute cycles.
This facilitates 10 mixing cycles per hour and illustrates the efficiency of the high speed Tweedy™ mixers. There are also new bread coolers and ovens that are more energy efficient and perfect the baking process.
“Our revamped high-tech bagging system is another aspect that adds to the overall efficiency,” says Marais.
In terms of safety, Marais says, “We are very proud of our low incident rate this year and in the past two years.” In 2015 the safety record was 1.25 LTIFR (lost time injury frequency rates) in 2016, 0.56 LTIFR, and in 2017 until June Albany recorded 0.14 LTIFR.
The improved safety measures include South African National Standards-approved walkways that have been installed to eliminate unsafe crossing of conveyors; there are isolators installed at all conveyors and electrical panels to ensure lockout procedures are adhered to.
“We have optimised the use of natural light with a raised roof to create an ergonomically friendly environment,” Marais says.
In addition, there is a water drenching system installed at coolers to prevent fire damage, and fire detection monitors are installed at key points around the plant.
Marais says: “We aim to improve our carbon footprint with new energy efficient lights, motors and ovens.”
Regarding water consumption, the new plant saves 3964 litres, a total usage of 11 877 litres compared to the 15 841 litres that were consumed previously. Waste water is recycled and used to wash the trucks.
Seshibe says: “It is our vision to become the best baked goods company in the Western Cape; best in quality (taste), best in service, best in technology, with the best team to do the job.”
“We have also improved our recipe based on recommendations from consumer tests and have enhanced the taste profile of our breads.
“Albany is an award winning brand in the bread category in South Africa and has several accolades under its belts.” These include the 2016/2017 TGI SA’s Kasi Star Brands; 2017/2018 Icon Brand Awards and the Sunday Times Top Brands Awards.
The bakery operates 24 hours, seven days a week and trucks leave the yard from 3am to 6am and services 5 000 outlets in its coverage area from large supermarket chains to independent retailers and spaza shops.
Seshibe concludes: “We are leaders in the baked goods sector and are confident that the Bellville upgrade with high quality equipment, energy efficient processes and tighter safety measures, will set the benchmark for all other bakeries in South Africa.”
Editorial contact:
Issued by Weber Shandwick South Africa on behalf of Albany Bakeries
Lola Lazarus
011 235 4675 / 083 271 5336
About Albany
Albany Bakeries have been dedicated to baking the freshest products since 1970, offering superior quality and nutrition that has been helping South African families start their day right. The largest range of baked goods is offered in South Africa from Albany Superior White and Brown bread, to low GI variants such as Albany Low GI White, Low GI Seeded Brown and Low GI Wholewheat, Albany Everyday White and Brown, Buns & Rolls. Kids’ favourite is Albany Superior Best of Both White Bread. Over the years, Albany Bakeries have proven to be leaders in innovation, long lasting freshness, great taste and superior quality. Albany launched Albany Ultima health range to meet the requirements of a healthy balanced lifestyle. Albany is the most awarded brand of bread having won awards such as the 2016/2017 TGI SA’s Kasi Star Brands; 2017/2018 Icon Brand Awards and the Sunday Times Top Brands Awards.
For more information on Albany products visit www.albany.co.za
