Henkel South Africa has reached a groundbreaking milestone in its sustainability journey with the official launch of its solar farm at its Alrode manufacturing plant. This transformative project ensures that 100% of the plant’s electricity needs during daytime operations are met through renewable energy sources.
The solar farm, which boasts a peak capacity of 1.8 megawatts, is seamlessly integrated into the plant’s energy grid, ensuring uninterrupted and efficient energy use. Beyond its operational benefits, this solar installation exemplifies Henkel’s commitment to tackling global climate challenges while making tangible contributions to South Africa’s national 2050 sustainability goals.
Revolutionizing renewable energy integration
The solar installation is grid-tied, allowing it to adapt to the plant’s energy needs in real time. During the day, all energy requirements are met directly by the solar farm, while at night, the plant leverages electricity from the grid, supplemented by Henkel’s existing renewable energy certifications. This dual approach ensures sustainability without compromising operational continuity.
By reducing reliance on the national grid, the Alrode plant anticipates a 70% reduction in daytime electricity consumption, translating into a significant decrease in greenhouse gas emissions. “Achieving 100% renewable energy sourcing for daytime operations is a proud moment for Henkel South Africa,” said Thelma Mamatlepa, Plant Manager at Henkel South Africa. “This project demonstrates that sustainable operations and economic efficiency can co-exist, making us a model for other industrial players in the country.”
Advancing Henkel’s Net-Zero Roadmap
The solar farm forms a key part of Henkel’s broader net-zero roadmap. In addition to achieving 100% renewable electricity for daytime operations, Henkel is accelerating efforts to reduce its scope 1 and scope 2 emissions. As part of this “Race towards net-zero,” Henkel aims to achieve full electrification of its Alrode plant by 2025/2026, including the installation of an advanced electrical boiler to replace fossil-fuel-based systems. These initiatives reflect Henkel’s steadfast commitment to addressing climate change and driving meaningful sustainability progress.
Innovative energy efficiency measures
The solar farm is the centerpiece of a broader energy optimization strategy at the Alrode plant. Over the past year, Henkel has implemented several complementary measures:
Optimized boiler systems: Henkel has overhauled its boiler operations, reducing energy consumption through full servicing, descaling, and the introduction of advanced water treatment technologies.
Improved insulation: By insulating mixers and steam lines, the plant has minimized heat loss, ensuring energy is conserved and efficiently utilized.
Smart production scheduling: High-energy-demand processes have been shifted to daylight hours to maximize the benefits of solar energy.
Recycling and water reuse: Process water is now reused for cleaning and other operational needs, reducing resource consumption.
LED lighting upgrades: Energy-efficient LED lighting is being rolled out across the plant, starting with warehouses and expanding to office spaces.
Collaboration and employee empowerment
The solar project was not only a technical triumph but also a demonstration of Henkel’s culture of inclusivity and collaboration. Employees on the shop floor played an integral role in identifying energy-saving opportunities, suggesting changes to processes, and championing sustainability initiatives.
“From optimizing motor operations to developing water-saving strategies, our employees have shown extraordinary ingenuity,” said Mamatlepa. “Their input reflects a shared commitment to sustainability and highlights the power of collective action.”
Looking ahead: a vision for the future
While the current installation does not include battery storage, Henkel has plans to evaluate future investments in energy storage to further enhance energy independence. Additionally, the plant’s energy monitoring systems will be upgraded to allow for real-time tracking and deeper insights into consumption patterns, enabling ongoing optimization.
The Alrode plant’s journey is part of Henkel’s science-based targets to achieve Scope 2 emissions reductions by 2030. It also aligns with South Africa’s broader energy transition, which seeks to balance economic growth with environmental stewardship.
“Henkel’s sustainability ambitions extend beyond our own operations,” said Mehmet Yilmaz, Director Operations and Projects Henkel Adhesive Technologies in the region Middle East and Africa. “We hope our efforts inspire other organizations to take bold steps toward renewable energy integration and environmental responsibility.”
A message to the broader industry
Henkel’s Alrode solar project underscores the importance of data-driven decision-making and employee engagement in achieving sustainability targets. The project’s success offers valuable lessons for other sectors, particularly in navigating South Africa’s energy challenges, including load shedding and rising electricity costs.
“At Henkel, sustainability is not just a target to achieve – it’s a responsibility,” said Veerabhadra Konakalla, Head of Sustainability, Health and Environment at Henkel Adhesive Technologies in the region Middle East and Africa. “Our solar farm is a testament to what’s possible when innovation, investment, and collective determination come together. We are proud to contribute to a cleaner, more sustainable future for South Africa.”
