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Case Study
PepsiCo Simba Chips
Penetron’s sustainable concrete solutions protect the Simba Chips waste-to-energy plant, ensuring durability and reducing carbon footprint.
Case Study
PepsiCo Simba Chips
Discover how Penetron’s sustainable concrete solutions protect the Simba Chips waste-to-energy plant, ensuring durability and reducing carbon footprint.
Project Context:
PepsiCo Simba Chips Innovates with Penetron Concrete Solutions
Simba Chips, a PepsiCo brand, has been a staple in South African households since 1956, known for its iconic potato chips. To align with PepsiCo’s global sustainability goals, the Simba Chips plant in Johannesburg introduced a cutting-edge waste-to-energy facility. This initiative addresses methane emissions and electricity dependency while producing renewable energy and natural fertiliser.
“Waste-to-energy technology offers significant sustainability advantages, and we needed infrastructure that could withstand extreme environmental conditions while delivering long-term performance,” explains Johan van Wyk, Technical Engineering Support for Penetron Africa.
The Challenge:
Durability in Aggressive Environments
The innovative waste-to-energy plant processes up to 11,500 metric tons of food waste annually, converting it into 800 kW of renewable energy. However, the facility faced key challenges:
- Microbial-Induced Corrosion (MIC): Acid-producing bacteria in gas zones threatened to deteriorate concrete structures.
- Durability: The infrastructure required protection against corrosion and heavy mechanical loads.
- Sustainability: The solution had to align with PepsiCo’s commitment to reducing environmental impact.
- Maintenance: Easy-to-maintain concrete structures were essential to minimise operational disruptions.
“MIC can rapidly compromise concrete structures, creating a critical need for long-term durability solutions,” adds van Wyk.
The Solution
Penetron Admix and Antimicrobial Protection
Key Benefits:
- Comprehensive MIC Protection: The antimicrobial admixture destroyed acid-producing bacteria, eliminating the root cause of concrete deterioration.
- Enhanced Durability: Penetron Admix waterproofed the concrete, reducing permeability and reinforcing resistance to chemical attacks.
- Seamless Application: Both admixtures were integrated directly into the concrete mix, requiring no additional coatings or post-treatment.
- Sustainability: By extending the service life of the concrete, Penetron reduced the project’s overall carbon footprint.
“Penetron’s admixtures offered unmatched protection and simplified the construction process, saving both time and resources,” says van Wyk.
The Implementation
Efficient, Eco-Friendly Integration
Penetron collaborated closely with Tharollo-Metsi (project consultants), Tecroveer (general contractor), and Metier Mixed Concrete (ready-mix supplier) to ensure the successful implementation of the solution.
Process Highlights:
- Mix Optimisation: Penetron Admix and the antimicrobial admixture were added during batching to all concrete elements of the facility, including the biodigester system, buffer tank, and live pit.
- Accelerated Construction: The seamless integration of Penetron’s products eliminated the need for additional coatings, reducing construction time significantly.
- Long-Term Protection: Penetron’s crystalline technology ensured that the concrete structures remained durable and resistant to environmental stressors.
“Thanks to Penetron, we overcame material inconsistencies and completed the project efficiently,” shares Tecroveer.
The Results
Durable, Sustainable Infrastructure
The Simba Chips waste-to-energy facility now operates with enhanced infrastructure that aligns with PepsiCo’s sustainability objectives.
Key Achievements:
- Time Savings: Construction was completed ahead of schedule.
- Cost Efficiency: Eliminated the need for high-maintenance coatings, reducing long-term expenses.
- Environmental Sustainability: Extended the service life of concrete structures, minimising environmental impact.
- Durability: The infrastructure resists MIC and other environmental challenges, ensuring reliable performance.
“This project demonstrated how Penetron’s solutions support PepsiCo’s sustainability goals while delivering long-term value,” concludes van Wyk.
Conclusion
Partnering for Sustainable Innovation
PepsiCo’s Simba Chips waste-to-energy facility highlights how Penetron’s innovative concrete solutions deliver durability, cost efficiency, and environmental harmony. As a result of this success, PepsiCo plans to integrate Penetron’s technology into other sustainable projects across its operations.
Ready to elevate your project with Penetron’s sustainable solutions?
Contact us today to learn how our crystalline technology can enhance durability, reduce costs, and support your environmental goals.
