For years, Shu Powders contended with an unreliable electricity supply, an issue that posed operational challenges and tested the resilience of our systems. But through strategic investments and a strong commitment to sustainability, we’ve made significant progress. We’re proud to share how we’re improving power reliability, enhancing system robustness, and supporting the global transition toward a cleaner energy future.
Understanding the challenge
In the past, inconsistent power supply, which included load shedding and voltage spikes and dips, affected several areas of our operations. These fluctuations highlighted opportunities to strengthen our systems and proactively reduce risk.
- Sensitive equipment such as PLCs, PCs, and analytical instruments were vulnerable to power variations, occasionally leading to downtime and repair costs.
- As a Major Hazard Installation (MHI) handling ammonia storage, we maintain high safety standards. Although safety systems performed as designed, the power fluctuations underscored the need to reinforce their reliability under all conditions.
- One notable incident involved a fire in the low-voltage (LV) room in January 2020, which investigations linked to unstable power conditions. This incident was contained safely and became a key turning point in our infrastructure strategy.
While control measures and safety systems were always in place, these events made it clear that a longer-term, more resilient solution was needed.
Our way forward
In response, Shu Powders developed a clear roadmap focused on:
- Strengthening power reliability through infrastructure upgrades
- Safeguarding critical systems with enhanced backup and monitoring
- Supporting sustainability by exploring cleaner, more stable energy sources
Step 1 Solar Power: Clean energy for a cleaner future
Our first major step was the installation of a solar power system, which now supplies approximately 20% of Shu Powders’ total energy demand.
This investment is doing more than just lowering our carbon footprint, it’s also reducing our reliance on the national grid, particularly during peak demand periods. By generating clean energy on-site, we’re creating a more stable, resilient, and environmentally responsible energy supply for our operations.
In March, we explored the project in detail, diving into its planning and implementation right up to early results and learnings. You can read more about the solar installation HERE .
Step 2 Dedicated Power Feeder with Maersk: A 97% drop in power events
At Shu Powders, consistent and reliable electricity is essential to ensuring operational efficiency, and, above all, safety. In the past, we experienced recurring power quality issues, particularly voltage dips and spikes, which were traced to a shared power line serving multiple industrial users in our area.
To address this, we joined forces with our neighbouring company, Maersk, to implement a long-term solution: the installation of a dedicated power feeder. This is a standalone electrical line that now supplies power exclusively to Shu Powders and Maersk, insulating us from fluctuations caused by other industrial loads.
Since the dedicated feeder was commissioned, we’ve seen a 97% reduction in power-related events, significantly improving equipment stability and reducing operational disruptions.
This collaboration demonstrates the power of industrial partnership, smart infrastructure planning, and long-term thinking in building a more resilient energy future.
Contractor Rockpower installing a dedicated power cable near Shu Powders main gate.
The key benefits for Shu Powders:
Improved Power Quality & Stability
With our own feeder line, Shu is no longer affected by the electrical noise or disturbances from neighbouring facilities. This ensures cleaner, more stable power for our operations.
Increased Equipment Reliability
Sensitive production and safety systems now experience fewer disruptions, reducing the risk of unexpected shutdowns or equipment damage.
Reduced Downtime
Since going live with the dedicated feeder, power anomalies have dropped by 97% (from 283 irregular events to just 9). This means smoother, uninterrupted production.
Enhanced Safety Performance
Stable power improves the performance of critical safety systems, helping to protect our people, processes, and products.
Better Operational Control
Isolating our power supply makes it easier to monitor, diagnose, and address any internal electrical issues quickly and accurately.
Step 3 Curtailment Program: No more load shedding
With our dedicated power line in place, Shu Powders is taking the next strategic step by enrolling in the National Curtailment Program, a move that strengthens our energy resilience and supports grid stability.
As national electricity demand continues to rise, especially during peak periods, utilities are increasingly turning to Curtailment Programs to stabilise the power network. These programs work by requesting enrolled industrial users to temporarily and voluntarily reduce power consumption, avoiding the need for widespread, uncontrolled outages.
For energy-sensitive operations like Shu Powders, sudden blackouts can result in production loss, equipment stress, and operational risks. By joining the Curtailment Program, we will secure three major advantages:
- Avoidance of unpredictable load shedding
Instead of being affected by unplanned blackouts, Shu receives advance notice of curtailment periods, allowing teams to prepare and adjust operations with minimal disruption. - Operational control and continuity
During curtailment, we reduce electricity usage by a manageable amount (typically 5–20%), ensuring that core processes continue running safely and efficiently. - Contributing to national grid stability
Our participation actively supports the national effort to balance supply and demand during peak times, promoting greater energy reliability for all.
Through this program, Shu Powders gains greater control over energy planning while helping solve a shared, national challenge.
Step 4 Our 2030 Vision: Increasing renewables to 50%
To achieve our 2030 carbon reduction targets, we’ve committed ourselves to increasing our renewable energy usage from 20% to 50% by 2027. This bold move is about more than meeting targets; it’s about leading the way in industrial sustainability.
We are exploring two main paths to make this happen:
- Electricity Wheeling
Buying renewable energy (such as solar power from Kimberley or wind energy from the Cape) from Independent Power Producers (IPPs) and delivering it to our facility via the national grid. - Direct Purchase from Eskom
We’re also closely watching the launch of Eskom’s Renewable Energy Offtake Programme target for 2027, which will allow companies to directly buy green electricity from the national utility.
Laying the Foundation for Energy Resilience and Sustainability
South Africa is still relying largely on coal-based electricity generation. Corporate efforts like Shu Powders’ support national commitments under the Just Energy Transition, helping to:
- Improve air quality
- Protect community health
- Create green jobs
- Stabilise the national grid
Sustainability is no longer optional; it’s a core business strategy. Investing in decarbonisation allows us to be more resilient to energy shocks and better aligned with the future global economy.
What started as a reactive response to unsafe power supply has transformed into a strategic sustainability roadmap. Thanks to this vision-turned-action, Shu Powders is now better protected against load shedding, ensuring safer working conditions, while making real progress toward our environmental goals.
Together, we’re proving that resilience and responsibility go hand in hand.
