Across our ISSA businesses, we are committed to maximising efficiency and sustainability by understanding market demands and producing products from the sugar-making process to meet those needs. Our pioneering project to repurpose boiler ash, a byproduct of our mills exemplifies the green circular economy of a sugar operation.
Under the leadership of Garth Lansdell, Commercial Manager – DURA-ASH, and Christian Rees, Strategic Business Development Director, and in close collaboration with site and agriculture managers, the team secured their first commercial contract with Country Stone to supply processed ash from our Sezela mill for brick-and-block manufacturing.
The driving force behind this success is the entrepreneurial and collaborative spirit of the team. Strong partnerships with Alson Kumalo, Sezela Estate Manager and Jurgen Witthoft, Cane Supply Manager, Noodsberg, as well as consistent stakeholder support from mill leadership and ISSA Exec, have been a crucial enabler. We have drawn on expertise from across our division, particularly the expertise of Andy Spetch, who led TOPSOIL at British Sugar and has been consulting on the project.
“This journey has been about discovery, agility, and collaboration. By working with external partners, we are bringing real value to the market.” – Garth Lansdell
This initiative is an excellent example of how we are driving our strategic priorities:
- Performance Culture: Encouraging innovative thinking and a proactive approach with demonstrable results.
- Operational Efficiency: Optimising every step—from cane to co-product—by establishing a pilot processing plant using second-hand equipment to minimize costs.
- Customer Focus: Delivering sustainable, high-quality materials that create new commercial opportunities.
Removal of boiler ash is crucial for the boilers to work efficiently, and as it is a low-density product, it can be costly to move. The team has focused on identifying commercial demand for products we can consistently produce at low cost and profitably sell. The opportunity is exciting as we have significant legacy stockpiles in addition to sizeable annual production.
As existing storage solutions approach capacity, it is imperative to explore new methods of managing ash to ensure regulatory compliance and maintain our license to operate. This project provides us with learnings we can take throughout the division, which not only help to address these challenges but also drive our ESG goals by minimising waste and reducing our carbon footprint. By repositioning ash as a valuable resource instead of waste, we also offer a sustainable alternative to traditional materials like river sand and quarry dust.
Success at Sezela is just the beginning. As we continue to refine our processes and explore new applications for ash, we are setting a benchmark for innovation and sustainability that can be replicated across our global operations. This initiative is a powerful reminder of what can be achieved when commercial insights and technical excellence meet a dedicated, entrepreneurial spirit.
As the team expands to other locations, they will continue to address the variability in ash composition, such as differences in particle size and properties, which will require us to adapt and experiment quickly to produce products that meet customer needs.
