BETA BRICKS Melfort Factory Information Brochure

1. Introduction

BETA Bricks, Zimbabwe’s largest clay brick manufacturer is expanding its operations. The company is a subsidiary of BETA Holdings, which also incorporates BETA Concrete and BETA Logistics. BETA Bricks is the first brick manufacturing entity in Zimbabwe to receive certification for integrated ISO management systems: ISO 9001:2008 (Quality Management System), ISO 14001:2004 (Environmental Management System) and OHSAS 18001:2007 (Occupational Health and Safety Management System). The Standards Association of Zimbabwe also approves all BETA Bricks products.

BETA Bricks is the flagship of the BETA Group, being the largest subsidiary by both production and market share in its sector of clay brick manufacturing. BETA Bricks offers a range of clay bricks ranging from the popular common brick and over 15 different types of face brick. The company currently operates a Steele 50 and Steele 75 plant, as well as a specials (face brick) plant in Mount Hampden. The Mount Hampden factories are currently operating at 93% capacity, producing about 170 million bricks annually, and there is need to install additional capacity in order to meet ever-growing market demand and to enable BETA to defend its market leadership position.

2. BETA Clay Bricks Market Demand Overview

2018 production is projected to be in excess of 170 million bricks, a significant growth from 2017 volumes, however, this, compounded with seasonal downturn during the rainy season, will be inadequate to meet market demand.

It is against this background that BETA Bricks has identified part of Blue Water Farm in Melfort as suitable land for the establishment of an additional clay brick factory. This factory will be the largest brick making plant in Zimbabwe.  The first phase of the project will involve the installation of a brick making plant, construction of a residential village for workers, as well as construction of an administration office.

The piece of land earmarked for the brickfield development measures 100 hectares and is located on a relatively flat piece of virgin land on which no other development has taken place (See Arial Map below)

Map

3. Description of the Project

Parameters Description
Type of Project Brick making factory (JC Steele 90 Factory Plant)
Capacity of the Project 155 million clay bricks annually
Geographic Location A 18.00220 S, 31 448620 E and Elevation 1496m B 17.991420 S, 31 452270 E and Elevation 1505m C 17.990110 S, 31.443460 E and Elevation 1483m D 17.998110 S, 31.440680 E and Elevation 1491m
Nearest Road and rail infrastructure Harare-Mutare Road about 20.5 Km from site in southern direction

Melfort Railway Station

Effluent Volume Peak /Maximum discharge of 5m3/day

4. Key Project Enablers

In order to commission the factory successfully, BETA has identified the following as key enablers for the project. It is envisaged that through smart partnerships and with the support of the local authorities and Government these enablers will be adequately addressed.

Enabler Specification Responsible
Water Peak /Maximum requirement of 100m3/day. The water requirement of the plant would be met by the three boreholes, which will be sunk on site. This will be the only source of water for the operations of the company on site. Beta Bricks will take the necessary steps to obtain Borehole water abstraction permit from the Zimbabwe National Water authority for drawing from the underground water. BETA
Roads The plant will be located 20.5km off the Harare-Mutare Highway Road from Rusununguko School turnoff.  The road is currently in very bad state of repair and will need to be resurfaced to allow for heavy trucks and additional traffic to area. Beta Logistics trucks carry loads of up to 30 Tonnes each when operating at full load. BETA/ GRDC/ ZINARA
Power 250 KVA. Power supply will be sourced from ZESA . BETA/ GRDC  /ZESA

*GRDC=Goromonzi Rural District Council

 5. BETA Bricks Value Proposition

BETA Bricks’ value proposition is anchored on a technology driven, cost leadership system centred on best quality products and providing a total customer solution.

BETA Bricks have a distinct competitive advantage over industry rivals through offering a high quality clay brick augmented with   superior value added logistics and ICT infrastructure and a unique customer relationship management model.

6. Production Capacity

The JC Steele 90 plant has a total installed capacity of 155 million bricks.

7. Total Investment

BETA Bricks will be investing in between US$8-10 million directly towards the establishment of the MELFORT plant. This will go towards the acquisition of core equipment, being the JC Steele 90 plant, ancillary equipment such as excavators, front-end loaders and grabbers, as well as for infrastructure such as power supply, construction of staff housing and civil works.

8. Employment Creation and Social Responsibility

At full capacity, BETA will create over 400 new jobs for the surrounding community. The offshoot business from having a vibrant manufacturing operation in the area also expects to result in a number of downstream businesses such that the local community will benefit socially and economically from the establishment of BETA Bricks plant.

The Group will also be extending its Corporate Social Responsibility programs in Education, Health and Environmental Management within the community.

BETA Bricks intends to collaborate with the relevant local authorities in the maintenance of local roads that link the project site to the main Harare – Mutare Highway. The company will also support the local clinic to ensure that it can accommodate the additional numbers stemming from the establishment of the business. In addition, BETA will also support local schools financially and materially in order to improve facilities to cater for increased enrolment emanating from the new workforce.

9. Environmental Impact

BETA Holdings is cognisant of the environmental impact of its operations and is committed to investing in sustainable environmental management programmes. BETA Bricks has already started implementing initiatives to reduce the negative impact of its operations on the environment, whilst the company has also extended various ISO 18001 initiatives adopted at its bricks, tiles and concrete plants such as land reclamation and the BETA Environmental Education Programme to the new operation.

10. Project Implementation

The construction phase is expected to take between 9 – 12 months. The project is expected to be commissioned in the second quarter of 2019.

Activity Date
Securing of land Dec 2017
Land clearance design and layout Feb 2018
Water(boreholes) April 2018
All administrative licensing and registration April 2018
Civils Jun 2018
Electricity supply and commissioning Oct 2018
Roads Oct 2018
Staff housing and workshop Jan 2019
Plant installation Feb 2019
Commercial production April 2019

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