Greenfields Poultry Feed — Operations Plan
The manufacturing facility will be located on a 5-hectare site in the Bronkhorstspruit Industrial Park, Gauteng Province. This location was selected based on the following strategic criteria:
Section 7 · Business Plan
Operations Plan
The manufacturing facility will be located on a 5-hectare site in the Bronkhorstspruit Industrial Park, Gauteng Province. This location was selected based on the following strategic criteria:
5,000 metric tons per month, with production volumes scaling from 18,000 MT in Year 1 toward full utilisation.
7.1 Facility & Location
The manufacturing facility will be located on a 5-hectare site in the Bronkhorstspruit Industrial Park, Gauteng Province. This location was selected based on the following strategic criteria:
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Proximity to Market: Within 100 km of the Gauteng poultry farming belt, the densest concentration of poultry operations in South Africa.
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Raw Material Access: 150-200 km from major maize production areas in the Free State and Mpumalanga, with direct access to the N4 and N12 national routes.
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Infrastructure: Industrial zoning with three-phase power supply, municipal water, and adequate road infrastructure for heavy vehicle access.
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Labour: Access to a semi-skilled and skilled labour pool in the greater Bronkhorstspruit/Tshwane area.
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Expansion Potential: 5-hectare site allows for future expansion to double current capacity.
7.2 Plant Layout & Equipment
The plant will be designed for an initial production capacity of 60,000 metric tons per annum (5,000 MT/month), operating on a double-shift basis. The facility will incorporate the following key production areas:
| Area | Floor Space (m²) | Key Equipment | Estimated Cost (R) |
|---|---|---|---|
| Raw Material Intake & Storage | 1,200 | Silos (6x 500T), intake pit, conveyors | R 12,000,000 |
| Grinding & Milling | 400 | 2x hammer mills (20 T/hr), screens | R 6,500,000 |
| Batching & Mixing | 350 | Computerised batching system, 3T mixer | R 8,000,000 |
| Pelleting & Cooling | 500 | 2x pellet mills (10 T/hr), coolers, crumblers | R 10,500,000 |
| Finished Product Storage | 600 | Bins, bagging machines (50 kg/25 kg/10 kg) | R 4,500,000 |
| Quality Control Laboratory | 150 | NIR analyser, moisture, fat, fibre testing | R 3,000,000 |
| Administration & Offices | 300 | Office block, meeting rooms, training centre | R 3,500,000 |
| Weighbridge & Dispatch | 200 | 60T weighbridge, loading bays | R 2,000,000 |
| Total | 3,700 | — | R 50,000,000 |
7.3 Production Process
The manufacturing process follows a scientifically controlled workflow designed to ensure consistent product quality and full traceability:
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Raw Material Receiving: Incoming grains and ingredients inspected, weighed, sampled, and tested for moisture content, mycotoxin levels, and nutritional composition before acceptance.
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Storage: Raw materials stored in designated silos and warehouses with temperature monitoring and pest control protocols.
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Grinding: Maize and other grains ground to specified particle sizes (600-900 microns for mash; 400-600 microns for pelleting) using hammer mills.
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Batching: Computerised batching system measures and dispenses ingredients according to pre-programmed formulations with accuracy of ±0.1%.
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Mixing: Ingredients blended in a 3-ton paddle mixer for a minimum of 4 minutes to achieve homogeneous distribution of micro-ingredients.
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Conditioning & Pelleting: Mixed feed conditioned with steam (80-85°C) and compressed through pellet dies at high pressure to form pellets of specified diameter.
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Cooling & Crumbling: Pellets cooled to within 5°C of ambient temperature and optionally crumbled for starter and pre-starter feeds.
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Screening & Quality Control: Finished product screened for fines, sampled for laboratory analysis, and held pending QC clearance.
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Bagging & Storage: Product bagged in branded packaging (10 kg, 25 kg, 50 kg) or stored in bulk bins for dispatch.
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Dispatch: Product loaded via weighbridge-controlled loading bays for delivery or customer collection.
7.4 Quality Management System
Greenfields will implement a comprehensive quality management system based on the following frameworks:
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HACCP (Hazard Analysis Critical Control Points) — Food safety management certified within 12 months of commissioning.
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ISO 9001:2015 — Quality management system certification targeted within 24 months.
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AFMA Code of Practice — Full compliance with the Animal Feed Manufacturers Association’s quality standards from Day 1.
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Act 36 of 1947 — Registration and compliance with the Fertilizers, Farm Feeds, Agricultural Remedies and Stock Remedies Act.
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Near-Infrared (NIR) Spectroscopy — Real-time nutritional analysis of both incoming raw materials and finished products.
7.5 Staffing Plan
The company will employ a total of 62 staff members at full operational capacity, phased as follows:
| Department | Year 1 | Year 2 | Year 3 | Monthly Cost Y3 (R) |
|---|---|---|---|---|
| Management & Directors | 4 | 4 | 5 | R 450,000 |
| Production & Operations | 18 | 24 | 28 | R 560,000 |
| Quality Control & Lab | 3 | 4 | 5 | R 150,000 |
| Sales & Marketing | 4 | 6 | 8 | R 280,000 |
| Administration & Finance | 4 | 5 | 6 | R 180,000 |
| Logistics & Warehouse | 5 | 7 | 8 | R 200,000 |
| Security & Cleaning | 2 | 2 | 2 | R 40,000 |
| Total Staff | 40 | 52 | 62 | R 1,860,000 |
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