Water recovery and sustainable brewing at SAB Ibhayi, South Africa
The Ibhayi SAB brewery fosters a circular economy. Energy, nutrients as well as process water are recovered from the brewery wastewater, limiting its environmental footprint. The new Ultra Filtration plant recovers 5.000m³ of precious water, each month.
UF Water Recovery Plant at Gqeberha, Saving water in South Africa – A Milestone in Sustainability
On the 9th of December, SAB ABInBev Ibhayi Brewery, in partnership with Waterleau, the Flemish government, and the United Nations Industrial Development Organization (UNIDO) , inaugurated a groundbreaking Ultra-Filtration Recovery Plant in Gqeberha, South Africa. This innovative project, designed and implemented by Waterleau, marks a significant step towards sustainable water management in the region.
The plant is the cornerstone of a circular economy initiative that addresses water scarcity, reduces environmental footprints, and supports local livelihoods.
Closing the Loop in Water Reuse
The brewery’s water recovery journey begins with treating wastewater in a process that extracts biogas and nutrients. These nutrients are utilized in a 2,000m² wetland system, enabling the growth of biocrops that provide fresh produce and employment for the local community. The Ultra-Filtration Plant completes the cycle, reclaiming water for reuse in the brewery’s operations.
“We started this project around 3-4 years ago, discussing what we could do to improve the water reuse at one of the ABI sites and decrease the environmental footprint,” said Laurenz Devers, Regional Managing Director for Africa at Waterleau. “With this project behind us, we close the loop of water reuse. The plant now produces 5,000m³ of potable water per month—equivalent to two Olympic swimming pools.”
Technology at the Forefront
Waterleau’s Ultra-Filtration Recovery Plant exemplifies cutting-edge engineering designed for water-scarce regions. The containerized, plug-and-play unit processes up to 250,000 liters of water daily, reclaiming it for essential brewery operations such as cleaning, cooling, and boiler water.
“This unit is turnkey, which means you can start it by the press of a button and have it run by itself without daily operation or assistance required,” explained Christopher Groenewald, Project Engineer at Waterleau. “It is also scalable, meaning it can be replicated for higher water recovery volumes if needed.”
Complementing the plant’s design is SmartLab, a digital platform that ensures real-time monitoring and optimal system performance. “This tech provides real-time data accessible from anywhere,” added Fortune Maharaj, Process Commissioning Engineer at Waterleau. “It ensures the system operates as intended, addressing water crises proactively.”
A Broader Impact: Environmental and Social Benefits
The project’s environmental benefits are clear: reducing water consumption by 0.25 hectoliters per hectoliter of beer brewed. In a region where water scarcity is a pressing issue, these savings translate into significant community impact.
“To put it in perspective, the Waterleau UF project gives us back 400 households’ worth of water each month,” said Ryan Verlandt, Technical Services Manager at SAB Ibhayi Brewery. “That’s a significant saving, especially in the Eastern Cape.”
The initiative’s social impact is equally noteworthy. Biocrops grown in the wetland system create stable employment opportunities for nine local workers. “We are creating jobs as well,” emphasized Jean-Luc Désire, CEO of Waterleau. “With this project, we show that economic growth and sustainability can go hand in hand.”
Collaboration Fuels Innovation
This project is a testament to the power of partnerships. Co-financed by Waterleau (35%) and the Flemish Government through UNIDO (65%), it demonstrates how collaborative efforts can drive global sustainability goals.
“On behalf of the Government of Flanders, I can say we are proud to support this project,” shared Nicolas Vandeviver, Deputy General Representative of Flanders in Southern Africa. “This is a technological solution that combines knowledge and expertise to solve global problems.”
A Model for the Future
As the Ultra-Filtration Recovery Plant begins its operations, it symbolizes a shift towards smarter, more sustainable resource management. Its success paves the way for similar initiatives worldwide.
“With this particular example, we can see that we don’t want to oppose economic growth and sustainability,” concluded Jean-Luc Désire. “Actually, they can be one and the same. At Waterleau, we aim to replicate this model in other locations to address changing market needs.”
The Waterleau UF project gives us back 400 households’ worth of water each month
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