Zambeef Mpongwe Flour Plant Expansion
Client
Zambeef Products PLCLocation
Copperbelt, ZambiaHighlights
- US$12 million construction value
- 150 tonnes/day processing capacity, producing 40,000 tonnes of flour annually
- Innovative soil replacement and raft foundation to stabilize poor soil conditions
- Optimized concrete road design for efficient space utilization
- Effective drainage design to manage high rainfall in a low-lying rural area
- Creation of 100 direct jobs and reduction of flour costs for local consumers
Overview
Zambeef Products PLC (Zambeef) is nearing completion of its cutting-edge flour milling plant in the Mpongwe District of the Copperbelt Province in Zambia. This US$12 million investment aims to increase Zambia's food production capacity, processing 150 tonnes of wheat daily to produce 40,000 tonnes of flour annually. By boosting food security, reducing production costs, and creating local jobs, the project is expected to have a significant positive impact on the local community and economy.
Main Project Features
- Four structures for the mill building, including intake copper, four silos, and a warehouse.
- Geotechnical design featuring soil replacement solutions.
- Geometric pavement design and optimized drainage systems.
- Comprehensive project management and coordination.
- Collaboration among Knight Piésold teams in Zambia, South Africa, and Namibia.
The Challenge
Zambeef, Zambia’s leading food producer, undertook the construction of a new milling plant in the rural Mpongwe District. The plant’s aim was to expand food production, processing 40,000 tonnes of flour per year to meet rising demand. However, the project faced several challenges:
- Geotechnical Issues: Mpongwe's rich farming soil is dispersive and ideal for crops but problematic for construction due to poor weather conditions that required special foundation solutions.
- High Rainfall and Flat Terrain: The site’s location posed drainage challenges and the need for robust water management systems. Compounding these issues, the project had to proceed through a rainy season, making strict adherence to timelines critical for success.
- Remote Location: The plant’s rural setting required careful planning for the transport of milling equipment from South Africa to Zambia, and project flexibility was crucial given the tight timeline, especially through the rainy season.
Our Approach
Knight Piésold, in collaboration with Zambeef, provided practical and sustainable solutions to overcome these obstacles. With input from teams in Zambia, South Africa, and Namibia, Knight Piésold designed a soil replacement system using a raft foundation to stabilize the site. Knight Piésold also implemented an optimized drainage system to handle the area’s high rainfall and flat terrain, ensuring uninterrupted construction through the rainy season. Knight Piésold’s holistic project management approach included the supervision of contractors like WBHO Zambia, ensuring close collaboration and efficiency.
The Results
As the project nears completion (currently 90% finished), the Zambeef Mpongwe Flour Plant is expected to be operational by October 2024. Once fully functional, the plant will process 150 tonnes of wheat per day, producing 40,000 tonnes of flour annually. This increased capacity will help reduce transportation and production costs, benefiting local consumers through lower market prices for flour. Furthermore, the plant will create 100 direct jobs, boosting local employment and fostering community development. Zambeef’s expanded production capacity will play a vital role in Zambia’s food security as the population continues to grow.
