Mondi South Africa cuts grid dependence with new turbine at Durban mill

SOUTH AFRICA – Global packaging and paper group Mondi has achieved a significant sustainability milestone at its Merebank mill in Durban, unveiling a new turbine that will allow the site to generate up to 60% of its electricity internally.

The move is expected to cut reliance on South Africa’s strained power grid while improving operational resilience and efficiency.

The project involved installing a condensing steam turbine, supported by new cooling towers, piping, and control systems, which utilize excess steam from the mill’s boiler.

Once the cooling tower upgrades are finalized, the turbine is projected to produce more electricity than the mill consumes, making Merebank effectively energy self-sufficient.

“This project is a game-changer for the mill,” said Donovan Naidoo, operations director at Mondi Merebank.

“By generating power onsite, we reduce our dependency on external electricity supply, reduce costs and take a step towards energy independence, climate resilience, and long-term operational stability.”

In addition to enhancing energy security, the new turbine will significantly reduce the mill’s carbon footprint, aligning with the company’s Mondi Action Plan 2030 (MAP2030) sustainability commitments.

Mondi has also invested in flood-proofing projects at Merebank to mitigate risks from extreme weather events.

These include the installation of flood gates and inflatable flood barriers that can be deployed to form water-catchment dams, protecting both mill operations and surrounding communities from flooding.

A global push for energy independence

The Durban project mirrors similar sustainability-driven investments across Mondi’s global operations.

In Slovakia, the company recently announced the construction of a biomass power plant at its integrated pulp and paper mill in Ružomberok.

Scheduled for completion in 2027, the plant will replace the site’s bark boiler, increasing energy self-sufficiency from 75% to 90%.

The Slovakian project also aims to deliver major environmental benefits, including a 50% reduction in nitrogen oxide (NOx) emissions and up to 83% less particulate matter compared to the existing system.

Beyond powering the mill, the new facility will bolster district heating in Ružomberok, helping reduce reliance on natural gas and supporting local communities.

With energy-intensive industries under pressure to decarbonize while navigating unreliable grids and climate risks, Mondi’s dual strategy of self-generation and climate resilience highlights how manufacturers are balancing business continuity with sustainability.

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