Opportunity
SEBA Foods, a leading soy and maize processing company based in Lusaka, Zambia, is currently expanding its production facility to meet the increasing demand for nutritious and affordable food products across Africa. The company manufactures a range of products, including Textured Soy Protein (TSP), High-Energy Protein Supplement, Extruded Snacks, Soy based beverages, and others. This expansion aims to increase production capacity, diversify product offerings, and strengthen SEBA Foods' market position.
The expansion project focuses on increasing production capacity, diversifying product offerings, and enhancing SEBA Foods’ competitive position. The expansion plan envisages TSP production in phase wise manner to reach total capacity to 2,000 tons per month. Additionally, the protein production line is being relocated and upgraded to achieve a capacity of 1,000 tons per month.
SEBA Foods is also exploring diversification into oil refining and animal feed production, unlocking new market opportunities. PMG has been entrusted to provide master planning, advanced process technology integration, cost analysis, and site execution to ensure a seamless and scalable expansion aligned with SEBA Foods’ growth objectives.
Solution
PMG's work begins with the development of a comprehensive master plan for both greenfield and brownfield sites, incorporating modern process technologies tailored to SEBA Foods' product portfolio to ensure scalability and operational efficiency. This plan will serve as the foundation for both immediate expansion and long-term growth. PMG is supporting SEBA Foods in the expansion project by conducting feasibility studies for new product lines, such as oil refining and animal feed production, in line with the company's diversification strategy.
During the design and engineering phase, PMG is focus on creating detailed layouts, utility distribution plans, and infrastructure designs to support scalable growth. These plans will accommodate the increased production capacity and future expansions. PMG project plan is having major constrain to optimally look into the upgradation and expansion plan that minimize disruptions to the existing production plan during construction.
PMG conducted phase-wise cost planning, analyzing civil, mechanical, process, and electrical work scope to ensure the project stays within budget while meeting client and investor expectations. This phased approach helps avoid over-investment in the early stages, aligning the expansion with demand growth and funding availability.
Once the design phase concluded, PMG is assist SEBA Foods with equipment procurement and site execution. By managing the procurement of key equipment and overseeing the implementation of the design, PMG ensures a smooth transition from design to operation, minimizing delays and maximizing production capabilities.
Outcome
PMG’s involvement in SEBA Foods' expansion project ensures a substantial increase in production capacity, aligned with a long-term growth strategy. By strategically planning for both immediate production boosts and future capacity needs, PMG helps SEBA Foods triple its TSP production capacity while maintaining flexibility for future expansions.
The master plan crafted by PMG establishes a robust infrastructure that supports both current and future product lines. The focus on scalability and efficiency enables SEBA Foods to meet the growing demand for its products across Africa, positioning the company as a market leader in soy and maize-based food products.
PMG’s detailed cost projections, investor presentations, and phased investment planning were instrumental in securing project approval. These efforts, combined with aligning the design to SEBA Foods' long-term objectives, facilitated a smooth project approval process, ensuring the success of the expansion.
Once completed, the expansion will enhance SEBA Foods’ competitive edge in the African market, enabling the company to supply a wide range of high-quality products to meet consumer demand. The increase in TSP production capacity, along with the relocation and upgrade of the HEPS line, ensures that SEBA Foods is well-positioned for continued success and profitability, solidifying its presence in the region.
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