investor site visit felixton paper mill - mpact · 2015 phase 1 khulisa2.15 2017 phase 2 2.15 2017...
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Investor Site Visit
Felixton Paper Mill29 May 2019
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OVERVIEW
Plastics
Mpact
Primary product categories
Recovered paper collection and recycling
Packaging and industrial papers such as cartonboard and
containerboard
Corrugated packaging
Paper bags, sacks and quick service restaurant (QSR) packaging
Primary product categories
PET bottle-to-bottle recycling
PET bottles and preforms, hot fill bottles, PET jars and closures
Large injection moulded containers
Trays, fast food containers and clear plastic films
Paper
CENTRES OF EXCELLENCE
Human Resources, Safety, Health, Environment, Energy
SHARED SERVICES
Finance, IS&T, Stellenbosch R&D
The largest paper and plastics packaging and
recycling company in Southern Africa
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Leading market positions with scale
to enable competitiveness on a
decentralised basis
5 062EMPLOYEES
Level 1*B-BBEE
OVERVIEW
40SITES
RECYCLING CENTRES
*Mpact Operations Pty (Ltd)
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Mpact’s integrated business model is uniquely focused on
closing the loop in plastic and paper packaging through
recycling and beneficiation of recyclables
OVERVIEW
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OVERVIEW
Over R1.6 billion invested over past three
years to Reduce, Reuse and Recycle
Remade acquisition
R130m
R130 million
Complements Mpact Recycling to expand collections of paper and plastic nationally
These initiatives are in support of the Mpact Polymers rPET operation and the Felixton paper mill
upgrade. Strategic objectives are being met.
Felixton Paper Mill rebuild
R800m
R800 million
Enhanced quality and product offering
Advanced lightweight containerboard
Increase capacity by 60,000 tonnes.
Replacement of virgin bagasse fibre with additional 100,000 tons of recycled fibre
Liquid Packaging recycling plant
R50m
New corrugator in PE
R150m
R150 million
Increase in capacity to service the growing citrus volumes in the region.
Ability to run lighter and stronger
Plastics converting projects
R155m
R140 million
New 5500T injection mould machine export jumbo bins; new integrated wheelie bin injection moulding
Recycling extrusion line for recovered crates and wheelie bins
2 new lightweight closure lines completed in 2017
rPET recycling plant
R350m
R350 million
PET recycling operation which produces rPET plastic for food grade packaging.
New washing equipment (R35m) has been ordered and is expected to be commissioned early 2019.
R50 million
Additional source of recycled fibre to the Spring’s paper mill.
Post-consumer liquid packaging feedstock still sub-optimum
reduce
recycle
recycle
recycle
recycle
reduce reuse
recycle
reduce
Paper
Business
8
76%
Paper Business Overview
Key products : Cartonboard
: Containerboard
: Retail ready packaging
: Regular slotted cartons
: POS packaging and displays
: Die-cut solutions
: Paper bags and sacks
: Quick service restaurant packaging
Key customers : Packaging converters (containerboard and cartonboard)
: Agricultural producers
: FMCG companies
: Quick service restaurants
: Other consumer and industrial packaging companies
Leader in recovered paper collection, production of
cartonboard, recycled containerboard and corrugated
packaging
Divisions : Recycling (17)
: Paper Manufacturing (3)
: Paper converting (corrugated and other) (13)
External Revenue (2018)
R8.3bn
EBIT (2018)
R694m
74%
PAPER BUSINESS
Paper bags, sacks and Quick
service restaurant (QSR)
packaging
Standard and customised cases, fruit and
vegetable trays, retail ready packaging
Cartonboard,
containerboard
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Paper Manufacturing
Geographic footprint Customers
Production capacity in kt
Additionally, Mpact distributes all containerboard products of Mondi Group’s Richards Bay Mill, selling
mainly into South Africa and selected markets in sub-Saharan Africa and Indian Ocean Islands
Mill/Plant Main productsCapacity 2019
(ktpa)
Piet Retief Linerboard and semi-chemical fluting 125
Felixton Fully recycled linerboard and fluting 200 – 215*
Springs Cartonboard and specialities 145
Containerboard and
cartonboard packaging
converters (internal and
external)
Geographic sales
Durban
Port Elizabeth
East LondonCape Town
Johannesburg
Springs Piet Retief
Felixton
Domestic,
86%
Richards Bay
Export,
14%
PAPER BUSINESS
*grammage dependent
Felixton
Paper Mill
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FELIXTON MILL
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Mill with combination of bagasse and recycled fibre
History of the Felixton Paper Mill
1950 1960 1970 1980 2020201020001990
1953 1973 1979
1984
2007
2011
Felixton Paper Mill was built
as Ngoye Board Mills,
2.2m wide machine
A new paper
machine was built,
4.5m wide
The Mill was purchased by
the Huletts Group
The Mill was purchased
by Mondi
Mondi demerged
from Anglo
American
MPSA demerged from
Mondi and listed on the
JSE as Mpact
FELIXTON MILL
2005Formation of Mondi
Packaging South Africa
(MPSA) with Shanduka as
the black empowerment
shareholder
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Investments through the years
FELIXTON MILL
1996 2020
1996Bagasse
washing plant
R30m
1998New headbox
and cleaners
R70m
2004Bagasse belt
washer R40m
2005Cationic starch
cooker R10m
2007Khulisa 1 RCF
Plant R80m
2008Paper Machine
Rebuild
(Khulisa 1)
R170m
2011Effluent Clarifier
R26m
2013New fully
automated
winder R40m
2015Phase 1
Khulisa 2.15
2017Phase 2
Khulisa 2.15
2017Increased
recycled fibre
storage facility
R25m
|------- R800m -------|
2000 2010
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Project Khulisa 2.15 – R800m investment
Transformation of the Felixton Paper Mill
• Increased capacity by 60,000 tonnes to 215,000 tonnes.
• Conversion from using bagasse fibre in our products to a
fully recycled fibre product.
• Improved product quality and cost competitiveness.
Bagasse Fibre Recycled Fibre
FELIXTON MILL
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Strategic Project Considerations
FELIXTON MILL
Cost competitiveness - Scale, energy efficiency and other variable costs.
Domestic market
demands
- Products: high quality lightweight recycled fluting and liners.
- Capacity: to meet growth requirements.
Fibre availability - Uncertainty regarding bagasse availability and supply (green energy
and drought).
Environmental footprint - Improve water and energy usage, effluent quality and increased
recycling.
Latest technology - Reviewed by international industry experts and major international
machine suppliers.
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Project benefits
› Attractive return on capital.
› Increased capacity by up to 60 000 tonnes:
- to between 200 000 and 215 000 tonnes grammage mix dependent.
› Enhanced paper strength properties (two-ply sheet and starch film size press).
› Improved cost and energy benefits positioning the mill as a low-cost paper
producer.
› Provides light weight production capability in-line with international trends.
› Environmental benefits include reduction in energy, water, COD and CO2 .
› Qualified for Section 12I tax incentive.
› Automated warehouse - efficient storage, stock control and productivity.
FELIXTON MILL
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Recovered fibre pulping process
FELIXTON MILL
Pulping Screening & Cleaning Fibre Preparation
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Paper making process
FELIXTON MILL
Sheet Formation & Dewatering Starch Application & Drying Winding, Finishing & Storage
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FELIXTON MILL 2015 PRE-REBUILD
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Automated Product Storage Warehouse
Production / Warehouse Interface
Warehouse Management System
Crane
Management
System
Operator
Interface
Roll Movement
System
Roll movement
Roll data
Set data
Shipping lists
Roll data change
Transport orders
Shipping lists
Inventory of storage
Status of the system
KPI (Input/Output)
Roll set information
Information of storage
and retrieval points
FELIXTON MILL
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Operational excellence in action
• Completed without injuries, on
time and within budget
• Project shut 46 days
• Start-up July 2017
• Focus on paper machine
availability and paper quality
• Head count reduced from 230 to
200 permanent employees
following closure of bagasse pulp
plant
FELIXTON MILL
50
60
70
80
90
100
110
Jul-
17
Sep
-17
No
v-1
7
Jan
-18
Mar
-18
May
-18
Jul-
18
Sep
-18
No
v-1
8
Jan
-19
Mar
-19
May
-19
Des
ign
Pap
er
Mac
hin
e A
ctiv
ity
(In
de
xed
)
Production Run Rates Per Product
Product 1 Product 2 Product 3
30%
40%
50%
60%
70%
80%
90%
100%
Ju
l-17
Se
p-1
7
No
v-1
7
Ja
n-1
8
Ma
r-1
8
Ma
y-1
8
Ju
l-18
Se
p-1
8
No
v-1
8
Ja
n-1
9
Ma
r-1
9
Ma
y-1
9
%
Eff
icie
ncy o
f P
ap
er
Mach
ine
Overall Equipment Efficiency
Material Efficiency (Quality)Time Efficiency (Availability) OEE Tend
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Project KhulisaPaper machine speeds achieved against design
FELIXTON MILL
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Energy benefits
• Equipment selection process
considered energy efficiency
• Exit from bagasse reduced electrical
and steam energy usage per unit
• Achieving 12I Tax Incentive Allowance
requirements of minimum 15% energy
reduction against baseline period
FELIXTON MILL
70
75
80
85
90
95
100
105
2012 2013 2014 2015 2016 2017 2018 2019
To
tal
En
erg
y I
np
ut
per
ton
ne
of
pap
er
pro
du
ced
(In
dexed
GJ/T
)
Total Energy Consumption
70
75
80
85
90
95
100
105
110
2012 2013 2014 2015 2016 2017 2018 2019
Ele
ctr
icit
y c
on
su
mp
tio
n p
er
ton
ne
of
pap
er
pro
du
ced
(In
dexed
kW
h/T
)
Electricity Consumption
50
60
70
80
90
100
110
2012 2013 2014 2015 2016 2017 2018 2019
To
tal
carb
on
dio
xid
e e
mit
ted
(In
dexed
to
nn
es
of
carb
on
/ t
on
ne
of
pap
er
pro
du
ced
)
Carbon Reduction
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Environmental performance
• Project design included the reuse of water
• Culture of continuous improvement of water
utilisation
• State of the art equipment ensures minimum
fibre loss thus improving wastewater quality
FELIXTON MILL
0
20
40
60
80
100
120
2014 2015 2016 2017 2018 2019
To
tal S
usp
en
ded
So
lid
s in
Waste
waste
r (I
nd
exed
To
nn
es/d
ay)
Wastewater Quality Improvement
50
60
70
80
90
100
110
120
2014 2015 2016 2017 2018 2019
Wate
r C
on
su
mp
tio
n p
er
ton
ne
of
pap
er
pro
du
ced
(In
dexed
kL
/T)
Water Consumption
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• Significantly enhanced paper profile
with substantially reduced mass and
moisture variations across the width
of the sheet.
• This is critical for box manufacturing
and enhances converter
performance.
• Overall improvement in paper
strength leads to a stronger box with
lighter weight paper.
Paper quality enhancements
FELIXTON MILL
Paper Profile
Variation (cross
direction 2 sigma)
Flat Crush
Resistance
(CMT)
Compressive
Strength
(SCT)
% Improvement 82% 10-12% 15-20%
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Mpact Paper and Packaging Innovation Centre
1st Qtr 2nd Qtr 3rd Qtr 4th Qtr
• Pulping
• Fibre morphology
• Chemical
optimisation
• Food Safety
• Benchmarking
• Competitive database
• Predictive testing
• Printing
• Correlation
between paper and
board properties
• Testing of boxes
to meet end user
performance
requirements
Paper
making
Paper
testing
Box
testing
Board
testing
FELIXTON MILL
Recycling
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Recycling
making a
difference
RECYCLING
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Recycling Overview
Staff numbers
Employees 626 (permanent)
Raw materials
Recycling Used and discarded paper and plastic
Products
Recycling Bales corrugated boxes, old
newspapers and magazines, office
papers and mixed papers, bottle glass,
cans, PET, LDPE, HDPE, PP and
liquid packaging.
Geographic Footprint - Recycling
Volumes
Recycling 630,000 tonnes in 2018
623,000 tonnes in 2017
607,000 tonnes in 2016
RECYCLING
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Nature of Recycling Business
Collecting recyclable
material is a local activity
Characterised by SMME's
who depend on reliable
off-take and prompt
payment
Provide a service in exchange
for access to material
• Technical advice
• Supply equipment – Mpact placed over
100 balers with dealers
• Reliable market – take all paper grades,
plastic etc.
Strong dependence on
good logistics
Some materials have become
globally traded commodities
Two main types of business
• Pre-consumer collections
• Post-consumer collections
RECYCLING
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Business objective
To provide our mills and operations with the
right quantity of material for recycling, at a
price and quality to maintain their
competitiveness.
RECYCLING
Recycling Business Overview
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Recycling Business Model
Paper Mills
and Polymers
Dealers
Pre-Consumer
Post-
Consumer
- Schools
- Offices
- Churches
- Kerbside
- Malls
- others
Independent
Collectors
Owner
Drivers
Reclaimers
Buy-Back
Centres
Mpact
Recycling
Branches
Tra
ns
po
rters
RECYCLING
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Recycling preparation for Felixton & rPET
2013 2014 2015 2016 2020201920182017
2014Investment in
equipment such as
balers, bins and
vehicles allowing us to
expand our collection
footprint
RECYCLING
2016Remade
acquisition –
allowing us to
extend our branch
network from 7 to
16 branches
2016 - 2019Springs RCF storage upgrade (3 phases -53 000m2 )
2019Pinetown branch –
allowing us to expand
our collection footprint
and now up to 17
branches
2017Felixton RCF storage upgrade
expansion (19 200m2)
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Key developments in global recovered
paper market
China used to import 45%-50% of globally traded recovered paper (26 million tonnes)*
Current Chinese imports for recovered paper estimated 11-12 million tonnes*
Environmental pressures
› National Sword 2017 – inspections especially around plastics
› Blue Sky 2018 – inspections; increased quality standards; quotas restricted
Consequence
› Recovered fibre had to find a new home
› Prices have dropped
› Leading to reduced exports from South Africa
RECYCLING
* RISI
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Partnerships
RECYCLING
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RECYCLING
Safety, health &
wellness and CSI
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CEO’s SHE PHILOSOPHY
ALL injuries, occupational illnesses, safety and environmental incidents are preventable
and our target for them is ZERO
SAFETY
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Mpact’s safety systems rely on three levels of intervention:
Primary and secondary interventions are guided by, and comply with, the Occupational Health and
Safety Act. Tertiary interventions are Mpact initiatives to lead change in safety culture.
Mpact’s Safety Structure
SAFETY
Primary Secondary Tertiary
Physical interventions to
provide a safe working
environment
Safety systems that control the
way people interact with work
hazards
Creating a safety culture
.WELL TEAM WHAT DO
YOU THINK ABOUT
THIS SAFETY
SITUATION
CULTURE GROWS
THROUGH
COMMUNICATION
AND FINDING
SHARED VALUES
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Mpact’s Safety Culture
SAFETY
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Working with the community in which we
operate
Felixton CSI Projects
› Career day for local schools
› Wellness days for local community
› Community garden project
› Water tank installation for community farmers
› Annual “Back to School” stationary collection
› “Build a home” project
CSI