Renowned for manufacturing premium quality beds, Restapedic Bedding has recently moved into their newly built factory at Number 1 Sleep Street, Sunway Industrial Park.
The factory was build as a single-roof solution to the four separate premises that they rented in the Msasa area, with the main offices being at 12 George Avenue. They also wanted to streamline the operations and to be able to expand their production capabilities and expand into the surrounding regions.
“Originally, we wanted to be on this side of town near Msasa and needed a big enough site to accommodate us. Unfortunately, we couldn’t find any suitable land available in Msasa, where we first started”, said Zyaara Omar, Restapedic Bedding Marketing Manager.
The old factory was only 8,000 square metres compared to the new factory at 17,000 square metres, showing the ambitions of the company. At 10,000 units per month, the production capacity of the new Sunway City factory is in excess of any other bed factory in the country.
Increased production capacity will also be achieved through the deployment of the latest production methods and this has been augmented by the purchase of new machinery for the new factory.
Before construction started, the land was a vacant 64,000 square metre plot. Phase 1 of the construction took 18 months and the initial build area is 17,000 square metres but will ultimately be about 25,000 square metres under roof when completed. Laying the foundation involved the removal of 500 tons of topsoil and overburden to make the site level.
Described by Omar as “very modern” in its architectural form, the building uses Chromadek with face brick up to three metres as part of the overall materials. Supported by steel facades and roofs, and rendering durability to the structure. Through a well-thought-out plant design layout the company has facilitated the smooth flow of materials and people through the factory.
Factory lighting is sufficient to meet the demand for the manufacturing process and for the safety of the employees. Complementing this is the use of natural lighting and ventilation to permeate and brighten the entire interior of the factory.
The large amount of space accommodates the required production levels, the number of employees, as well as the amount of storage space required, all of which has more than doubled. The material handling section has been positioned to suit the smooth flow of materials throughout the factory from the receiving area right through to the purpose built loading bays.
The HVAC system provides a comfortable working environment for the employees while protecting the factory equipment from extreme temperatures. About 150 staff enjoy great welfare, with their personal belongings allocated adequate restrooms, change areas with showers, a fully fitted canteen and a clinic. Visitors will find the 1 acre-sized parking bay for their convenience.
The project contractors were A M Machado Pvt Limited Building Contractors, a family-owned and run construction company with over 50 years of experience.
For the factory’s environmental sustainability goals, Restapedic Bedding uses alternative sources of power for the factory; all the security and administration sections will be completely off-grid. A reservoir holding 6,5 million litres has been installed by Zim Dam Construction for rainwater harvesting. The water harvesting facility can harvest and supply 100% of the water used on site.
“We aimed to only use local contractors and specialised trades for all the construction. We have also replanted over 400 indigenous trees on site,” said Omar.
A large fire hydrant matches the capacity of the factory. While a fuel garage and truck workshop space have been allocated adjacent to the factory. Modern pavers have been used for a sizable part of the yard, ensuring ease of access for the vehicle fleet.
Restapedic Bedding has developed the factory for the future and allowed for any further expansion as there are large open spaces in and around the building. The factory is part of the company’s overall manufacturing strategy as it will fulfil its 25-year plan when fully completed.
Text by Martin Chemhere
Images by Fotohaus
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