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BY THE WAY ...

Publisher: Martin Wells (martin@summitpub.co.za) Editor: Tessa O’Hara (tessa@summitpub.co.za) Editorial assistant: Heather Peplow (heather@summitpub.co.za) Financial manager: Lisa Mulligan (lisa@summitpub.co.za) Designer: Bronwen Moys Blinc Design (bronwen.clarke@gmail.com) Summit Publishing cc t: +27 (21) 712 1408 f: 086 519 6089 c: +27 (82) 822 8115 e: saplastics@iafrica.com Postnet Suite 42, Private Bag X16, Constantia 7848, Cape Town, South Africa 70 Newton Drive, Meadowridge, Cape Town

www.saplastics.co.za

GAUTENG Lowrie Sharp t: (011) 793 4691 f: (011) 791 0544 c: 082 344 7870 e: lowrieplasticsmedia@absamail.co.za KZN Lynne Askew t: (031) 764 2494 f: (031) 764 0676 e: lynne@leafpublishing.co.za Printed by: Tandym Print, Maitland, Cape Town SA Plastics Composites + Rubber Technology is published six times a year and focuses on these industries in South and southern Africa. We welcome news, articles, technical reports, information in general and photographs about events and developments related to the plastics industry. The views expressed in the magazine are not necessarily those of the publisher. Views expressed are not necessarily those of the Plastics Converters Association, Institute of Materials or Association of Rotational Moulders either. Copyright: All rights reserved. ISSN number: 1684-2855 (ISDS Centre, Paris) Summit Publishing: CK 9863581/23 VAT reg: 4600187902

Plastics Institute

Association of Rotational Moulders of South Africa

of Southern Africa

Plastics Converters Association

PET Plastic Recycling

Plastics Federation

South Africa

of SA

Institute of Materials

National Clean-up & Recycle Week takes place from 16–21 September – During September we’ll see packaging leaders united around a common goal, litter-free streets, rivers and beaches, by mobilising local communities to make a difference in their own neighbourhoods. Read more about this on page 36

Polymer trading is risky, so why make it even more risky? OUR comment in ‘By the Way’ in the June-July issue covering containers and stones led to points on trader margins on imported polymers that beg a response. Polyolefins, vinyls and styrenics are all commodity polymers, traded in huge quantities around the world, formerly quoted on the LME and more recently on the Dalian Commodities Exchange. Weekly pricing newsletters such as ICIS and Platts and daily movement reports such as Polymerupdate.com all contribute to a particularly transparent market. Local merchants mark-ups of 30% are fantasy land and even a 6% margin would result in street parties here in Bedfordview. Any converter receiving an overseas price of even 10% lower than the market should look at such an offer askance; he is simply not going to get what he expects. In reality, polymer trading is a business more aligned to trade finance than melt flow, to dollars rather than density. There are three risks: firstly the exchange rate, secondly the receivable performance and finally the risk that the price moves from the minute the purchase is confirmed until the goods are finally sold (and hopefully, paid for). Huge volumes are bought and sold, just in South Africa, requiring millions of Rands of working capital. These tons are sold into a market where the domestic producers set the price. There are a number of well established specialist polymer traders in South Africa. They have the skills, experience and resources and have supplied polymers of reputed quality for many years. ‘Ping Pong Polymers from Peking, velly cheep?’ No thank you”

Y

Dick Coates, MBT, Johannesburg

Painczyk did a lot for training I was surprised that the tribute to Albi Painczyk published in your last issue made no mention of his dedication to plastics education and training in the Western Cape. After all, PISA bestowed a rare Honorary Life Fellowship on him for his contribution to education and the industry in general. He served on the PISA/Cape Technikon advisory committee for many years. He used his influence to ensure that up-to-date moulding machinery was available for the benefit of students and he served on the Plastics Industry Training Board. He showed immense dedication and commitment to the training cause. Francis Hannay, formerly of Nampak R+D (now retired)

METHING HAVE SO … IF YOU TO SAY de: if you e bright si Look at th wisdom to of m ge e have som to us at ease write impart, pl com a. ic fr ia s@ saplastic


Volume 11 No 4

AUGUST – SEPTEMBER 2013

Contents Find out more at www.saplastics.co.za

INDUSTRY NEWS APS Plastics goes electric

6

Berry & Spence gets into co-ex, seamlessly

8

West African Group returns to WAI

12

Intrinsys launches product lifecycle management business

14

NG Engineering thrives 46 years on!

16

HDPE boats offer solid solution for tough marine environment

20

24

46

DESIGN Lighten up! KVR Design starts

22

ASSOCIATION NEWS IPSA seminar: Future of packaging in SA will challenge all involved

30

PSPC: Automated collection of recycled polystyrene

38

50

K2013 European plastics industry is cautiously optimistic

52

70

WORLD Graham Engineering acquires Welex

86

SPORTS Wits team to compete in Solar Challenge

96

74

ON THE COVER APS Plastics founder, Herzel Saban, is intent on becoming more efficient in order to be more competitive and fend off the plethora of ‘Made in China’ products that have been overwhelming many Western manufacturers. Read more on page 6.

www.apsplastics.co.za


THIS ISSUE Martin Wells

, Publisher

Companies turning to R+D, developing synergies

with partners to ride out economic doldrums Focus on energy efficiency, leaner, more ‘intelligent’ production HE ‘K’ (kunststoffe, plastics) show has for more than half a century been one of the main catalysts for development in our industry. In recent years this role has been challenged by the emergence of a very active industry in China, but – not to be outdone – the Europeans (and specifically the industry in Germany) have come up with new and relevant technologies again this year, for K2013.

COMMENT

T



I was privileged recently to attend a preview for the show in Düsseldorf, during which some of the top international equipment and material suppliers gave presentations about the technologies to the group of about 80 journalists. Two things became clear: firstly, almost all the other journalists reported that conditions in their domestic markets were difficult, which is a salient reminder that Southern Africa is not the only place in the world where conditions are tough … not that that’s going to help you much! But it is a reminder that the grass is not always greener on the other side. The second noticeable trend is more relevant: the presenting companies reported that they have been using the period during the recent economic doldrums usefully: while sales have slowed, these companies have turned to R+D as well as developing synergies with their partner companies. Obviously a business has to have the capital in reserve to ride out such ‘quiet’ phases. The result is that some of these companies are emerging stronger and healthier from the economic downturn, plus with at least some new technology. New technology will hence again be spotlighted at this year’s K (16-23 October), with the main focus being on improved energy efficiency and leaner, more

AUGUST / SEPTEMBER 2013

‘intelligent’ production. Read more about this in our preview of the K (pages 52-69). First Tech crisis The crisis unfolding with the First Tech group has shocked many to the core, certainly those at the affected companies in the group. We hear the losses are over R3-billion, and possibly going up. Gazelle Plastics, a pipe manufacturer in Krugersdorp; Ogatin, a profile extrusion operation in Industria, ‘Some of these Johannesburg; and Flexicon, companies are also a pipe manufacturer and emerging stronger piping component manufacand healthier from turer in Witbank, were forced the economic to close their doors almost immediately. downturn, plus These businesses had been with at least some trading quite favourably, we new technology.’ hear, until recently, but the cashflow crisis left no room for escape. Besides the staff, the other big losers are the material suppliers … and we hear that some of them were in for substantial sums. Is this a sign of the times? It’s hard to imagine how financial institutions could have been unwitting in the process. For ordinary folk, it’s even more puzzling how the situation could have run so wildly out of control. For most of us, it’s probably a reminder about the modest pleasure of keeping things simple and sobre.


INDUSTRY NEWS

JUST BRIEFLY First Tech disaster THE three plastics companies in the First Tech group have been plunged into disarray following the group’s meltdown. First Tech has gone into liquidation with debts estimated to exceed R3-billion – and by the time you read this the figure may be higher. Such was the scale of the implosion that the doors shut almost immediately at Gazelle Plastics in Krugersdorp, Ogatin in Industria and Flexicon in Witbank. In all, 21 companies have been caught in the maelstrom. These shutdowns are not something we are familiar with in the industry and come as a shocking reminder of the financial fragility that businesses can be exposed to. Trading conditions had appeared to be favourable for the three businesses as recently as February this year, when a rebranding charade was carried out, with Gazelle for example, becoming First Tech Piping and Ogatin being renamed First Tech Lighting. At that stage the financiers must have realized that the problem was of a massive scale and demanded a contingency strategy. But all was in vain: First Tech CEO Jeff Wiggill was apparently murdered in June, when a body was found with fatal bullet wounds next to his Bentley at a deserted spot in Soweto.. An estimated 5000 people are affected by the shutdowns, with a significant number of these individuals being from Gazelle, Flexicon and Ogatin – and it’s quite likely that the scenario will see many flooding into the job market.

Boitumelong BEE group buys Otto OTTO Waste Systems of Isando, Johannesburg, the manufacturer of wheelie bins, waste skips and other technical components, has been bought by Boitumelong Holdings, a BEE company. The transaction – of the Otto business as a going concern – includes all the equipment and property as well as the 50% share in the business owned by the parent company, Otto Industries Europe. Boitumelong has also entered into a technical agreement with Otto Industries Europe. Current MD Rob Lerena has agreed to a management contract indefinitely. www.ottowaste.co.za

6 AUGUST / SEPTEMBER 2013

APS Plastics goes electric Saban says the only way to compete is to become more efficient ‘GIZMO’ range manufacturer APS Plastics of Cape Town is taking China on … well, not literally: APS Plastics founder Herzel Saban is intent on becoming more efficient in order to be more competitive and fend off the plethora of ‘Made in China’ products that have been overwhelming many Western manufacturers.

APS Plastics products can be found throughout the country on the shelves of all major South African retailers such as Shoprite and Checkers, Pick ‘n Pay, Makro and Game. Internationally, the company supply wholesalers and retailers in the United Kingdom, Australia, The Middle East and Africa. Their extensive product range, which includes over 50 products across multiple categories, is manufactured at a state-of-the-art factory in Killarney Gardens. Saban, a diesel engineer by training who started APS in 1995 (he’s been involved in injection moulding since

Exports into Africa appear to be growing Survey suggests that manufacturers are keener to supply into Africa A SURVEY by Manufacturing Circle suggests that South African manufacturers are beginning to export more into Africa than was the case until quite recently, and plastic product manufacturers are likely to be among those looking northwards for sales opportunities. The 50 respondents to the first-quarter survey indicated that the share of exports to Africa had become larger than those to Europe, the traditional export destination for locally manufactured products, as well as to South Africa’s fellow BRICS bloc partners, Brazil, Russia, India and China. In fact, that was probably never in doubt – of the four countries, exports to only Brazil have been noticeable. About 26% of responding companies – including large and small manufacturers from a diverse range of industry subsectors, from fabricated metal products and

electrical machinery to furniture and chemical products – reported that 81-100% of their exports were going to African markets. Nearly three-quarters of those surveyed indicated that they had at least some exposure to Africa through exports. By contrast, more than half of the respondents did not export any products to regions such as Europe, North America, South America, Japan, China and India. Somewhat surprisingly, nearly 60% of respondents indicated that they did not export to Europe at all, while 82% indicated that they had no export exposure to the Chinese market. Pan-African Investment & Research Services economist Dr Iraj Abedian, who oversees the compilation of the survey for the Manufacturing Circle, said that it was apparent that Africa had become a ‘significant’ market for South African manufacturers. Trade and Industry Minister Dr Rob Davies recently told Parliament that negotiations for


PHOTO: MARTIN WELLS

Electriffic! – APS founder Herzel Saban and business partner Sakkie Wolfwaardt with the new fully electric Sumitomo Demag ‘IntElect’ 100-ton machine that is helping the Cape Town company further improve its efficiency levels

1981), has been building up the business nonstop since, to the point where today it supplies its products on a proprietary basis. It also handles the packaging and ships direct from the plant, with exports comprising a large share of its sales. With machine cycle times approximately the same in the East and West, and with other variables being similar too, Saban decided some years ago that the best strategy was to use the most efficient machinery. As a result APS Plastics recently purchased an all-electric Sumitomo-Demag

a trilateral free trade agreement between the members of the Southern African Development Community, the East African Community and the Common Market for Eastern and Southern African were proceeding. The T-FTA would combine the markets of 26 countries, with a population of nearly 600-million people and a combined gross domestic product of $1-trillion. Another key message to emerge from the latest Manufacturing Circle survey was the primacy of the domestic market in the fortunes, or otherwise, of South African manufacturers. The lion’s share of domestically produced goods was still consumed within the borders

injection moulding machine. The company has previously used fully-electric as well as ‘hybrid’ (part electric) machines, but according to Saban the Sumitomo-Demag ‘IntElect’ system is proving to be a good choice: it’s very responsive, uses 40-60% less electricity and is achieving faster cycle times. The technology has long and rich origins: Sumitomo Corporation of Japan, has been in existence since 1630 (yep, that’s not a mistake) and has been producing heavy machinery since 1888. It’s been producing electric machines since the 1990s. Demag’s parent company, Ankerwerk of Germany, introduced its first injection machine in 1950, and has carried on the process of development ever since. The tie-up between the companies in 2008 has now resulted in the combination of these traditions and technologies, resulting in highly refined equipment. This refinement, speed and cost savings in a machine that functions optimally and offers uninterrupted production is exactly what APS Plastics was after to meet their high-output of products. www.apsplastics.co.za

of the country, with 70% of respondents indicating that domestic sales accounted for 60% or more of total sales. A new section to the survey also showed that the majority of respondents considered government’s local-procurement programme to be important in the process of maintaining and growing their manufacturing operations. However, it also indicated that only a small number of surveyed firms had actually benefited from current programmes www.manufacturingcircle.co.za

SA auto exports to Africa – Exports of South African-manufactured vehicles into the rest of Africa could ‘easily triple’ in the next 10 years, according to the National Association of Automobile Manufacturers of SA. Naamsa says, however, that the increase in SA cars sent north would depend on a ‘grand free trade area’ becoming a reality and infrastructure improvement ARTICLE: ENGINEERING NEWS

Currency sways present problems Rand devaluation not good, but it’s been worse before THE rand’s recent devaluation has come as a shock to many in the industry, but it’s happened before – and been even worse in previous cycles. The currency’s deterioration in recent months saw it go from roughly R8 to the dollar to over R10/$. This creates problems for importers of material and equipment, although generating opportunities for better returns for exporters. The rand hit its historical nadir – to date – in December 2001 when it reached R13.85 to the dollar. The SA Chamber of Business motivated for a commission of inquiry into the trend, and that seemed to have an effect and led to a recovery: by the end of 2002 the currency had dipped below R9/$ once more. And by the end of 2004 it was trading at R5.70/$. The average rate in 2012 was R8.20/$. But it’s not only the rand which has suffered: the currencies of virtually all ‘emerging economies’ have declined in value recently: the currencies of India and Turkey – economies which can be roughly compared to that of South Africa – hit historical lows in July. Several factors affect the rand’s value, including the movement of money out of the emerging markets, the size of the country’s current account deficit and problems in the mining sector (the value of gold and platinum has declined steadily in 2013), but one of the main reasons is that the rand is one of the few ‘emerging market’ currencies that can be bought or sold in reasonable quantities. Last year an estimated R126-billion was traded in currency futures, which was 26% higher than in 2011. And this year trading has been even more intense: the highest single monthly turnover – R41-billion – was recorded in May. And, to complicate matters, it appears that many people don’t understand the ‘money market’ processes. However, the JSE has introduced innovations to enable lay investors to better understand and become involved. It has introduced JSE Virtual Trader, a simulated trading platform on the JSE website that enables potential investors to experience realtime trading. www.psgonline.co.za

AUGUST / SEPTEMBER 2013 


INDUSTRY NEWS

JUST BRIEFLY Capital funds lift stake in Astrapak CORONATION Asset Management and Capital Management have increased their holdings in Astrapak group, whilst Royal Bafokeng’s group has further reduced its stake. The Bafokeng group’s shareholding fell to just 3% (from nearly 17%), while Coronation has increased its holding to 29.33% and Capital Management to 6.41 percent. Royal Bafokeng was the original BEE investor in Astrapak, when it made a large investment in the group in the 1990s, but it’s shareholding has been gradually reduced. One of the main issues for Astrapak at present appears to be whether insurers will redeem its R56-million damages claim following the fire at East Rand Plastics in January.

DPI expands reach in Africa DPI Plastics is expanding its geographical footprint across Africa, after entering into a supply agreement with the DRC (Democratic Republic of Congo) branch of AST International in May. AST is a joint venture between the Dawn Group – a specialist in the manufacture and distribution of branded hardware, sanitaryware, plumbing, kitchen, engineering and civil products – and Saffer, which supplies South African manufactured and branded plumbing and sanitaryware products to retailers, builders merchants, plumbers merchants and hardware stores. Dawn and Saffer established AST International in 2007 to become the dominant brand vehicle and first choice supplier of quality branded building products in Africa. DPI Plastics is a member of the Dawn Group. The AST branch office in the DRC is expected to open in August. “As a South African based company with 100% owned or joint venture factories in Namibia, Botswana, Angola, Tanzania and Mauritius, DPI Plastics has identified additional neighbouring markets that hold considerable potential, and the company plans to be among the first to take advantage of this gap in the market, and to play a role in the continued economic growth on the continent,” said DPI Plastics export manager, Rajesh Naval. www.dpiplastics.co.za 8 AUGUST / SEPTEMBER 2013

Berry & Spence gets into co-ex, seamlessly LESSONS learned from previous capex projects were beneficial for Berry & Spence, a Cape Town film and bag-making business, when it decided to enter the co-extruded film market. It was obligated to get into co-ex to keep up with the market, but how to do it? The company operates several blown film lines, but its most recent purchase – a line from the East – had, although attractively priced, taken five months to get up to full production. That was costly and stressful, and also threatened to jeopardize the loyalty of some customers. Berry & Spence had not been involved in multi-layer work before, so the challenge was specific. After analysis the team decided to go for top European technology and eventually opted to buy the line from Macchi of Italy. This was a major investment – the Macchi COEX flex® 3 line cost in excess of R8-million – and, according to Berry & Spence managers Russell Mackintosh and Lionel Bantam, the whole project has gone smoothly since. PHOTO: MARTIN WELLS

Sasol plans HDPE project in USA Signs MOU with INEOS Olefins & Polymers USA SASOL has signed a memorandum of understanding (MOU) with INEOS Olefins & Polymers USA to form a joint venture to manufacture HDPE in the United States. “This partnership will leverage the expertise of two global players in the chemical market. Together we will develop a worldscale HDPE plant which will allow us to monetize ethylene and supply a high quality product,” said André de Ruyter, Sasol senior group executive for global chemicals and North American operations. “The joint venture expands on our greater North American strategy and will complement the products produced from the ethane cracker and derivatives project in south-west Louisiana.” The envisaged plant will produce 470 kilotons per annum of bimodal HDPE using

Innovene™ S process technology licensed from INEOS Technologies. The intention is to produce a limited number of grades allowing high grade efficiencies. “This joint venture demonstrates INEOS’s continued commitment to the HDPE market and to growing end-use applications that benefit from bimodal technology. It enables two global companies to integrate with each partner’s upstream businesses the leading bimodal slurry technology on a world-scale asset,” said Dennis Seith, CEO of INEOS Olefins & Polymers USA. The final investment decision is expected to be made in the first half of 2014, with startup of the plant expected at the end of 2015.

www.sasol.com


Berry & Spence makes industrial size baler bags, lamination films (for the pouch market), shrink films and bags-on-a-roll (it uses a number of state-ofthe-art bag making machines), and the new Macchi COEX flex® line is creating additional capacity in all these areas

Going co-ex – Lionel Bantam, Russell Mackintosh and Jenny Schutte, members of the Berry & Spence management team, with the new Macchi COEX flex® line

locence layers allow for the production of Bantam first underwent training at the thinner films. Mackintosh says the ExxonMacchi plant in Milan, and then the Italian Mobil metallocene materials it’s been using company’s technicians spent a fortnight at have proved very effective in this respect. the B&S plant in Ottery during the installaThe line can make films up to a whoption and commissioning. ping 200 microns, but the majority of films The line, using Macchi’s patented produced are only a fraction of that. co-extrusion die heads, can run at up Co-ex production also allows to 400kg/hr, the equivalent for the use (encapsulation) of of five of the company’s a recycled layer, which is older extruders, so the “Running at potentially a cost saving. project represents an up to 400kg/hr, exponential leap for the Spence’s legacy company. The fact that the project The successful managethe line can produce represents an ment of the co-ex project at higher rates than exponential leap for is at least partly a result of its nameplate capacity the company.” the legacy of outgoing MD was also greeted with Gordon Spence, who semisatisfaction! retired in 2009. Spence, who Berry & Spence makes still visits the plant once weekly industrial size baler bags, (or when required), employed most of lamination films (for the pouch marthe individuals on site and also enabled ket), shrink films and bags-on-a-roll (it uses the management team to gain equity in a number of state-of-the-art bag making the business. The result is that Berry & machines), and the new line is creating adSpence has a small but committed team ditional capacity in all these areas. drawn from the local community. The big plus with the co-ex capability is that it creates the opportunity to downwww.berryandspence.com gauge: the use of reinforcing or metal-

Ex-Husky boss Robert Shad starts again FORMER Husky founder and CEO Robert Shad has, after five years of the behind-the-scenes development, started a new company, Athena Automation. The Toronto-based business has launched a new design of hybrid injection machines and side-entry robots aimed at PET preforms, packaging, closures, medical, and technical parts. Athena’s initial focus is on PET preforms. It has teamed up with SIPA of Italy to provide total solutions, from preform and bottle development to filling and palletizing. SIPA is handling sales, service and integration of PET systems on a worldwide basis under the XForm label, while Athena will provide those functions under its own name for other applications. Athena assembles its machines from purchased components, many of them custom-made by local suppli-

ers in Canada. It employs 58, including some former Husky and Engel staff, in a 10,000m² plant. After retiring from Husky and selling majority ownership to a venture capital firm, Schad started Athena Automation in 2008. His goal was to try some new approaches to creating a “customizable platform focused on energy efficiency, process repeatability, and reduced space requirements”. Its first product is a 150-ton machine, five of which have been sold. The first commercial unit will be displayed by SIPA at the Drinktec exhibition in Munich in September and at the K2013 fair in Düsseldorf the following month.

Robert Schad’s encore after Husky was founding Athena Automation to pursue new design ideas for flexible, customizable, energy-efficient injection presses

www.athenaautomation.com

AUGUST / SEPTEMBER 2013 


INDUSTRY NEWS

Mpact grows profits under difficult trading conditions Revenue of R3.5 billion up 9.7%

Industry still seek meeting with Govt on bag levy PLASTICS│SA, working together with bag manufacturers around the country, continue to try to engage constructively with government to resolve the bag levy issue and to work out an effective solution acceptable to all parties. Anton Hanekom, Executive Director of Plastics│SA, said that the industry body had recently received a letter back from government in response to Plastics│SA’s submission about the gazetted legislation to increase the bag levy. He said that the letter indicated that there was still some misunderstanding on government’s part about the industry’s issues with the increase to the bag levy. “We need to meet the relevant government representatives and discuss the issues face to face,” said Hanekom. Hanekom said that he was optimistic that a meeting with the relevant government representatives would happen in the near future. “The plastics industry wants to engage constructively with government on this issue and discuss with them how to use the bag levy more effectively,” he added.  AUGUST / SEPTEMBER 2013

MPACT has reported an increase in underlying operating profit and underlying earnings per share of 6.1% and 20.9% respectively despite difficult trading conditions. Revenue increased by 9.7% to R3.5 billion for the six months ended 30 June 2013, attributable to volume growth in plastics and higher average selling prices. External sales volumes increased by 2.5% over the same period last year. Underlying operating profit rose 6.1% to R236 million. Mpact CEO, Bruce Strong says that the company’s key measure of return on capital employed improved to 15.5% from 14.1% in the comparative period in 2012. “Operating conditions remain characterised by subdued GDP and consumer spending growth that in turn is driving an intensely competitive trading environment,” says Strong. He says the weaker rand provided some relief for Mpact by improving the relative competitive position of its manufactured products compared to imported

substitutes, and also supported growth in packaging for fruit exports, which remained robust in the first six months. “However, these benefits were offset by increases in raw material prices, most notably plastic polymers, pulp and chemicals, which were not fully recovered in our selling prices,” says Strong. Revenue in Mpact’s Plastics business increased by 17.7% to R969 million mainly due to sales volume growth of 14.1%, of which about 1% was due to acquisitions. The preforms and closures business benefited from good growth in the beverage sector, while growth in the agricultural sector benefited the styrene and bulk bin businesses. Underlying operating profit decreased by 7.6% to R34.3 million compared to prior period due primarily to the under-recovery of raw material cost increases during the period. www.mpact.co.za

Survey reveals:

perceptions of SA declining THE Southern African-German Chamber of Commerce and Industry’s (SAGCC) recent survey of European enterprises in South Africa has revealed poor perceptions of the current economic climate. Based on the current trend, the SAGCC index will soon reach the level of 1998 when it was -57, its lowest point in 14 years. The SAGCC Index is an important tool in the analysis and portrayal of the current economic situation, and is interpreted in a manner similar to the IFO Business Climate Index. The survey took place between February-June 2013 and included member companies and other enterprises active in the South African market. European companies participating in the survey hailed from Austria (13), Denmark (6), Finland (3), France (22), Germany (95), Italy (9), Netherlands (15) and Sweden (1). A total of 163 surveys were completed.

Responses The perception of the current economic climate has declined from +31 points in 2010 to -35 points in 2013. About twice as many companies regard the climate as ‘bad’ when compared to the previous survey. This has constrained decisions on new investments and job creations. Concerns about Broad-Based Black Economic Empowerment have increased since 2010. More than 60% of the respondents view B-BBEE as a costly exercise with no tangible benefits for their day-to-day businesses. Respondents underline the lack of competence of the civil service (78% of negative opinions) and the excessively high level of corruption (seen by 87% as ‘pessimistic’ or ‘very pessimistic’). • It must be noted that the survey did not take place under any specific political or economic circumstances, which could have influenced the results.


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Two-million litre PVC-lined reservoir a first in SA

INDUSTRY NEWS

PVC liners flexible and stronger than HDPE or LDPE STEELFAB Water Solutions recently demonstrated how plastics can help combat shortages of drinking water when the company installed a PVClined panel reservoir of 2 million litres – the first of its kind in Southern Africa. Steelfab manufactures its own PVC liners in-house which are certified and passed to international AS/NZS 4020 Drinking Water Standards. The PVC liners are flexible and Steelfab claim that they are 1.8 times the strength of HDPE or LDPE commonly used in other water storage tanks. Mariana Strydom, business development manager at Sinvac in Pretoria who represents Steelfab in SA, says PVC also withstands both higher and lower temperatures than HDPE/LDPE and is the only material that truly welds together. She adds that the PVC liner eliminates a common stress factor that is usually associated with non-flexible liner materials. The PVC liners that were manufactured and installed for www.steelfab.com.au

the panel reservoir of 2 million litres are up to 33m in diameter, with the highest to date being 13.48m high. Two different materials are used for the manufacturing of PVC liners for water tanks. Both the materials are exclusive to Steelfab Water Solutions: 0.55 Potable Aquatex PVC: Potable water tank liners are manufactured from 0.55mm thick PVC material made especially for harsh climate conditions and tougher than any other PVC on the market: This material will stretch but is not prone to shrinking. It is difficult to puncture and can be repaired under water. The PVC weld is the strongest part of the water tank liner, unlike woven materials and HDPE/LDPE. 0.8 Duplex UV Stable PVC: This UV stable material is used in harsher environments where the ultra violet exposure is high and there may be large variations in the temperature in a single day. It is not suitable for potable use. As a laminated product, it is very strong and hard wearing.

www.sinvacplastics.co.za

The Aquadome water storage reservoirs are manufactured from 1.00mm BMT Bluescope Zincalume, which makes the tank walls up to 40% thicker than many other tanks on the market

The PVC liner eliminates a common stress factor that is usually associated with non-flexible liner materials. The PVC liners that were manufactured and installed for the panel reservoir of 2 million litres are up to 33m in diameter, with the highest to date being 13.48m high

West African Group returns to WAI Metmar group sells polymers business back to former owners WEST AFRICAN GROUP (WAG) has been sold to West African International (Pty) Ltd. The polymer, chemical and rubber trading business had been operating as a division of Metmar since 2008, when it was bought as a package from West African Ventures and West African International – so the change effectively returns (WAG) to its former home and the founding partners, Jack Doherty, Brent Hean, Rob Macnab and Willie Esterhuizen have regained management control .  AUGUST / SEPTEMBER 2013

The business will now be a division of West African International, a privatelyowned company. Metmar said in a statement that it had identified certain core areas of its business and, with the ongoing process to dispose of non-core investments, found it to be an opportune time to sell WAG. WAG supplies a range of polymers – including polyethylene, polypropylene and polystyrene grades, synthetic and natural rubber, chemicals and engineered carbons – to convertors in South Africa

and neighbouring states. Management advised that WAG had grown substantially over the last few years and the brand had been well supported by its principals, service providers, staff members and customers. “We are very thankful for this loyal support and hope to continue growing the business into the future, whilst the core focus will remain on the sales and distribution of polymers, chemicals, engineered carbons, synthetic and natural rubber,” said the statement.


where quality is action

A-PET


INDUSTRY NEWS

PHOTO: LOWRIE SHARP

Intrinsys launches product lifecycle management business Intrinsys took the opportunity to exhibit at the recent TASA conference specifically for the West Rand tool makers. Lucian Biscop (engineer, seconded from France), Gary Longshaw (business development manager) and Joe Pepper (senior engineer, seconded from the UK) assisted with the development and formation of the company

Fully supported by Dassault Systèmes INTRINSYS LTD has new South African offices in Johannesburg delivering Product Lifecycle Management (PLM) solutions. Operations will initially be centred on the Johannesburg offices and training centre, but will also cover the major industrial areas around Durban and Cape Town. “We are very excited about our new South African operation,” said Darren Cairns, Intrinsys’ Director. “This development is fully supported by Dassault Systèmes who have helped us to define the requirement for their products and identify the potential customers who will appreciate the unique blend of service and support we offer.” Dassault Systèmes PLM products available from Intrinsys include: CATIA: CADaAuthoring software serving all leading industries ENOVIA: Product Data Management – CAD and BOM management, work-

flow and collaboration SIMULIA: Analysis product family including Abaqus DELMIA: Manufacturing (2D & 3D machining) 3DVIA: Integrated documentation production Intrinsys will also introduce MIDAS’s mechanical and geotechnical analysis products into South Africa using their extensive consulting skills to provide the best product for each customer. In conjunction with the support, consultancy and implementation services surrounding PLM, Intrinsys offer a range of engineering services that can be employed on a part-project or programme basis: Design (concept and/or technically advanced) Analysis (mechanical Linear and/or non-linear)

Manufacturing (prototype development) Training Centre Intrinsys offer experienced trainers with a comprehensive range of product user training, including customer specific advanced level training. Training is delivered by working engineers who include ‘best practice’ and ‘hints and tips’ from a variety of leading industries within their training sessions. www.intrinsys.co.za

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Ask about our GreenAble range of films and contribute towards saving our environment.


NG Engineering thrives FAMILY run N.G. Engineering in Germiston has not just survived 46 years in the plastics injection moulding industry, but has thrived, and continues to do so under the guidance of brothers Harald and Udo Niederbroker. Founded in 1967 by Hans Ulrich Niederbröker, the company was first situated in President Street in Johannesburg, before expanding and moving to Jeppestown. Hans passed away tragically in 1971 and his wife, Inge, took over the running of the company until her death in 1988. Hans and Inge’s sons Harald and Udo took over the reins and in 1991 relocated to larger premises in Germiston. Being involved with many different sec-

tors of the industry over so many years the brothers and their team have a vast knowledge of plastic converting, use of materials and application of materials to suit the products their clients require. N.G. Engineering is involved in mining, petrol chemical plants, advertising as well as the electrical and lighting sector. They manufacture a variety of products, ranging from boxes to seals. The company’s plastic injection moulding plant has machines ranging from 15 to 320 tons. A fully equipped tool room compliments the moulding plant and all moulds are manufactured and maintained in house. N.G. Engineering are currently launching one of their newest products – an all plastic

spotlight, specifically designed to accommodate the new E27 led spot lights available. Energy saver bulbs can also be used in the spotlight. The spotlight can be manufactured in any colour or combination of colours, enabling it to either stand out or blend in with its surroundings. Employees and management are highly skilled, ensuring that only the best quality products are delivered and production schedules are always met. www.ngengineering.co.za

PHOTO: LOWRIE SHARP

INDUSTRY NEWS

46 years on!

 AUGUST / SEPTEMBER 2013

N.G.ENGINEERING

In the spotlight – The N.G. Engineering team with examples of their new all plastic spotlight, specifically designed to accommodate the new E27 led spot lights available. Management team members from left are: Harald Niederbroker, Udo Niederbroker with his son and daughter Stephan and Monika Niederbroker, and far right, plant manager, Daniel Mittler

TOOL & DIE MAKER , PLASTIC INJECTION MOULDERS

ALL PLASTIC SPOTLIGHT

IMCD buys Chemimpo IMCD (Internatio Mueller Distribution Company) group has purchased Chemimpo in South Africa, the diversified materials supply and logistics company. IMCD is a global leader in the sales, marketing and distribution of speciality chemicals and food ingredients. It also supplies detergents, pharmaceuticals, coatings, personal care products and lubricants. The deal gives IMCD access to the polymers and rubber markets, areas where it was not involved before and where Chemimpo is strong. Chemimpo supplies the Borealis/Borouge HD cable and pipe materials, DSM’s range of synthetic rubbers, PVC coating materials as well as a range of other polymers and adhesives. IMCD’s head office is in Rotterdam, Netherlands; Chemimpo’s HQ is in Randburg.

All colours available Designed for E27 LED spots Fits E27 energy saver bulbs On / off switch (on request)

inquiries@ngengineering.co.za

011/ 825 6028

www.imcdgroup.com


INDUSTRY NEWS

JUST BRIEFLY

First turbines for PETCO wins prestigious award

Cookhouse wind farm THE first consignment of 16 turbines for the Cookhouse wind farm has arrived at the Port of Ngqura, near Port Elizabeth in the Eastern Cape. The delivery of these turbines, which feature 44-m-long blades, was the first under the Department of Energy’s (DoE’s) Renewable Energy Independent Power Producer Procurement Programme (REIPPPP). Construction on the Eastern Cape-based Cookhouse wind farm, developed under the first round of the REIPPPP, started in February and will, when completed, be the largest in Africa, consisting of 66 Suzlon 2.1 MW turbines with a combined installed capacity of 138.6 MW. This would provide enough energy to power about 145 000 low income homes, with power expected to be supplied to the national power grid by the second quarter of 2014. The wind farm was developed by African Clean Energy Developments and is owned by a consortium of African infrastructure investors, comprising Apollo; the African Infrastructure Investment Fund 2; the Infrastructure, Developmental and Environmental Assets Managed Fund; Afpoc; and the Cookhouse Wind Farm Community Trust. The project was financed by Standard Bank of South Africa, Nedbank and Futuregrowth Asset Management, and employed Suzlon Wind Energy South Africa – a subsidiary of the Suzlon Group and the fifth largest turbine supplier in the world – as primary contractor. • ARTICLE FIRST PUBLISHED IN ENGINEERING NEWS

www.suzlon.com

The first consignment of 16 turbines destined for the largest wind farm in Africa, have arrived at Coega Port, near Port Elizabeth in the Eastern Cape. The arrival of these turbines, featuring impressive 44-metre-long blades, is the very first under the Department of Energy’s Renewable Energy Independent Power Producers Procurement Program (REIPPPP) announced in 2010

PETCO has won an award at the Mail & Guardian’s annual ‘Greening the Future’ awards in recognition of its extended producer responsibility programmes. The M&G’s annual ‘Greening the Future’ awards, which have been held for the past 10 years, celebrate environmental best practice in South Africa. The awards showcase innovation in renewable energy, action to combat climate change and strategic management of natural resources. Congratulations to all the PETCO shareholder members who continue to support and fund EPR in the PET plastic bottle sector.

Astrapak sells Alex White & Co ASTRAPAK, the JSE-listed plastic packaging manufacturer, has sold Alex White & Co (Pty) Limited as a going concern to Tadbik Pack SA (Pty) Limited for an undisclosed amount. Astrapak CEO Robin Moore said the impact of the disposal will not significantly affect the earnings or assets of the Astrapak Group. “We are delighted to have been able to sell this business as a going concern to Tadbik who is a recognised player in the label market. The sale is therefore not only good for us as a business, but we believe is very positive for the industry as a whole, our customers and the staff who were all transferred to Tadbik as an integral part of the transaction,” said Moore. The sale was effective from 1 August.

Lanxess closes Isithebe rubber chemicals plant LANXESS is re-aligning its production network and portfolio for its Rubber Chemicals business unit. The business unit will streamline its product range as some products have reached the end of their life cycle. The production of the aging inhibitors Vulkanox 3100 and Vulkanox DPPD, which are produced at the Isithebe site in South Africa, will be discontinued and the plant will be closed. The site closure in Isithebe will affect 40 positions and efforts to seek responsible solutions for all affected employees will be taken into account. Further measures at the Rubber Chemicals business unit are affecting sites in Belgium and the US. The Lanxess Isithebe plant began operations in 1979. The plant produced Vulkanox 3100, an antioxidant for the tyre industry. Such antidegradants are chemicals which protect the vulcanized rubber products against damaging external influences like oxidation, ozone and heat. Situated in northern Kwazulu-Natal, this production site formed part of the Lanxess Rubber Chemicals business unit. Other rubber chemical production sites are situated in Europe, the United States of America and India. www.lanxess.com  AUGUST / SEPTEMBER 2013


HAITIAN HUAYUAN˄ ˄SOUTH AFRICA˅MACHINERY (Pty) Ltd Haitian enjoys an excellent image worldwide as a brand name. On the one hand our quality, highgrade machines fulfil the requirements for precision and profitable efficiency demanded by our international customer base, and Haitian is valued for its customer-orientated and comprehensive service.

Haitian injection moulding machines and technology components are currently manufactured at eleven locations, depending on the construction series, category of clamping force and customer specifications. For this we have automated production lines and wellmotivated employees, in a total production area of about 500 000 square meters. Our lean organizational structures, efficient operating procedures and ultra-

modern equipment guarantee the high production efficiency and flexibility with which we are able Our Details: Managing Director: hsh@mail.haitian.com After Sales Service Manager: jv.haitian@gmail.com Office & Spares Manager: lsg.haitian@gmail.com Service Engineer wwq.haitian@gmail.com Website: www.haitian.com

to meet customer needs on attractive terms, with proven quality yet in the shortest possible time. Now Haitian Huayuan (South Africa) Machinery (PTY) LTD extends this excellent and reliable service as part of Haitian International, to South Africa directly, eliminating all agents. Our new offices are in JHB, Spartan, where we strive to continue to build customer relations and pro-vide excellent service and support through a great team, Hu Shuinhui (General Manager), Johan Venter (After Sales and Service Manager), Wu Wenqing (Service Engineer), Leonie Grove (Office and Spares Manager), and Grant Pattinson (Sales, Service Engineer – PE).

Since Registration in October 2012, We have exhibited at Propak 2013 in Nasrec, at KITE 2013 in Durban, and have shown phenomenal growth in a short period of time, with a large existing Customer base, new contracts and further prospects in the pipe line, definitely leading to further expansion of Haitian in South Africa. Article by: Leonie Grove

Hu Shunhui

+27-799170588

Johan Venter

+27-726681322

Leonie Grove

011 974 1127

Wu Wenqing

+27-724383102

A Haitian MA800 in operation:

Some Injection Moulding Machines in stock – SA Factory:


INDUSTRY NEWS The Rhino 670 undergoes sea trials near Simons Town

HDPE boats offer solid solution for tough marine environment Rigid, robust, reliable craft from RHINO MARINE THE range of boats fabricated from standard HDPE sheet and pipe by Rhino Marine are proving to be a practical option for the rugged offshore rig, oil spill intervention and ocean search and rescue sectors. The vessels – ranging from 5.9 to nearly 10,5m long – are produced in 12-50mm HD sheet and pipe. The 50mm sheet used in sections of the hull results in a formidable craft, and the ‘virtually indestructible’ tag is hence the main appeal of these ocean-going craft which are seen as an alternative to rigid-hulled inflatable (RIB), aluminum and composite hull boats. The biggest advantages of the HD craft is their low maintenance, rugged construction, corrosion and chemical resistance and the fact that they are slightly heavier than RIB boats, meaning that they tend to be more stable in the water and can withstand heavy swells. Rhino Marine is building the boats at its premises in Airport Industria, Cape Town. In operation since 2005, the company manufactures eight variations:

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the smallest Rhino 590 is 5.9m in length and weighs in at 600kg while the largest, the Rhino 950, is 9.58m long and weighs 2750kg. The bigger models can reach speeds of up to 36 knots and are suited for personnel transfer, dive support, search & rescue as well as military and naval use. The company is busy investigating bringing out a fast rescue boat range, and is also able to develop customized boats for specific operations. The boats are mostly exported to West Africa, Dubai and Europe. However, there has been recent interest from an oil spill intervention company in Port Elizabeth. Invest in R&D, develop new prototypes Rhino Marine constantly invest in R&D and develop new prototypes. The company has a dedicated team of engineers who collaborate with a naval architect from Icarus Marine and together develop all the prototype boats. Rhino Marine is a member of the South African Boat Building Export Council

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(SABBEX) and have also developed boats with the South African Marine Safety Authority (SAMSA) which ensures that the company maintains the necessary safety requirements. Cutting and HDPE welding Rhino Marine recently bought a CNC cutting machine. 2D Autocad fabrication drawings are programmed into the CNC cutting machine which then cuts out all the parts required for fabricating the boat from the HDPE plate. The pontoon piping is placed in a specially fabricated jig and the pipe sections are extrusion welded together. Once the pontoon structure has been welded together, the bulkhead frames, transom, deck and all parts of the HDPE super-structure are prepped and welded together to create the hulls. Tack welding and extrusion welding methods (using Fusion 2, Fusion 3C and Triac S welders from Leister Technologies AG, a German company) are used to join the sheet and pipes. In excess of 180kg of extrudate is used to complete all the welds on each boat. www.rhinomarineboats.com

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From left: 1) Rhino Marine recently bought a CNC cutting machine which cuts out all the parts required for fabricating the boat from the HDPE plate. Pictured here are Luc Herman (marketing & business development manager), Wayne Gerstner (factory manager) and Clinton Carels (workshop foreman). 2) The wide beam jig with the soon-to-be pontoons of a new Rhino 800. 3) Finishing touch to the welding of a hull’s plate to the pontoon. 4) Luc Herman (marketing & business development manager) in front of a Rhino 590 EHD, the company’s best-seller. 20

AUGUST / SEPTEMBER 2013


liam.chegwidden@polysaf.com and alan.wassung@polysaf.com (Cape Town) (Cape Town) www.exxonmobilchemical.com liam.chegwidden@polysaf.com, kelly.dewet@polysaf.com and alan.wassung@polysaf.com


PHOTOS: MARTIN WELLS

DESIGN

Lighten up!

Subtle yet simple solutions – Long, slender and styled in wave-like contours, the lamp shades are produced in Perspex acrylic. In the inset we see Kenneth with one of the mouldings, produced by Reflex Products, prior to installation

KVR Design starts – Flowing contours and subtle illumination achieved with acrylic sheet CAPE Town designer Kenneth van Rensburg took the plunge recently and started his own business, KVR Design. Kenneth graduated as an industrial designer in 2007 and at first entertained ideas of an exciting career in automotive design and was fortunate, while on a visit to Europe, to spend time at the Jaguar factory in England, where there is a massive focus on design. But back home he’s had to focus on

everyday products, first at Protoform in Atlantis, and now on his own. He recently landed a job designing lights for a Foreshore office development by Frame + Adams Architects, and came up with this solution. Long, slender and styled in wave-like contours, the lamp shades are produced in Perspex acrylic. The advantage of using plastic sheet is obvious – at 7.5kg per unit – it’s

UPCYLING, repurposing, reconditioning, call it what you will, but we love it when we see the results of creative minds working towards sustainable solutions, especially with plastics! Two Portuguese designers, tired of watching clothes hangers tossed aside after a brief life on the rack, decided to reclaim them as functional art. Diogo Agular and Teresa Otta of LIKEarchitects rescued 2,000 colourful IKEA children’s hangers that were destined for the landfill and designed a technicolor Chromatic Screen for the 2012 Oporto Show, the most prestigious event for interior design and architecture on the Iberian Peninsula. And guess what the lampshade is made from? Plastic teaspoons – lots of them!

 AUGUST / SEPTEMBER 2013

far lighter than glass, and the soft but effective lighting achieved is also a big plus. The mouldings hang approximately 5m above the foyer. KVR’s style is to achieve subtle yet simple solutions.

www.kvrdesign.com www.reflexproducts.co.za


Visit our stand for the latest equipment Hall 15 Stand D22

Objet Eden Family

Objet Desktop Family

Hall 2 Stand G23

Sumitoma Demag will be exhibiting at the K, 16-23 October 2013 in Düsseldorf, Germany, Hall 15 Stand D22, the world’s premier trade fair in plastics and rubbers. Demaplastech’s, Jacques Kleynhans, a veteran in the South African plastic industry will be at their stand to show you what’s new and exciting! Demaplastech also represents Stratasys in South Africa, an all rounded 3D printing machine supplier, exhibiting in Hall 2 Stand G23. Have a look at this exciting technology.

TEL: +27 (0) 11 462 2990

SOLUTION

FAX: +27 (0) 11 462 8229

MACHINERY (PTY) LTD

e-mail: jacques@demaplastech.co.za


DESIGN

Thinking Design on show at University of Johanneburg UJ Industrial Design Alumni Exhibition 2013 show their best THINKING DESIGN is an inversion of the term ‘Design Thinking’ and highlights the hidden thoughtfulness that goes into a design or the solving of a problem. And proof of this way of thinking was very obvious at the University of Johannesburg’s Industrial Design Alumni Exhibition which opened

at the university during early August. Thinking Design focuses on the physical artifacts generated by this process from five professional industrial designers and alumni from the UJ Department of Industrial Design. In industrial design practice these artefacts include: research, sketches,

renderings, development models, user-testing, engineering, development prototypes and final manufactured prototypes. Five alumni exhibited their work – Peter Harrison, Jonathan Fundudis, Trevor Hollard, Rowan Mardghum and David Holgreaves.

Jonathan Fundudis & David Holgreaves – snapp design Engage Wine Rack manufactured using ASB – the wine rack is made up of magnetised pods which can be put together in different formations, giving the user the ability to define the layout and number of pods. The wine rack is produced in 7 colours

Splay Salad Servers manufactured using Copolyester (Tritan) – the form of the salad servers is reminiscent of Plasticine. The servers are produced in 10 colours, including clear which is an attribute of Tritan

Trunk jewellery tree manufactured using silicone and solid wood – the rubber like surface allows jewellery to be stored without fear of being damaged or scratched. The jewellery tree is produced in six colours

Two-faced coasters manufactured using PVC – a set of six double-sided coasters with six illustrated characters showing two sides to their character. An encapsulated magnet in each coaster assures that they all remain together or may be displayed separately on a metal surface, such as a fridge for quick accessibility  AUGUST / SEPTEMBER 2013


Zodiac Baracuda Mars wheel design for SA market

The Zodiac Baracuda Mars automatic pool cleaner which won an SABS design award in 2003. The parts were designed and developed for client Henk & I cc (contracted by Zodiac Poolcare). The pool cleaner work was completed whilst working for Henk van der Meijden www.harrisondesigns.co.za

Peter Harrison – Harrison Designs

Zodiac Baracuda Mars pool cleaner for fine debris, washable filtration part

Zodiac Baracuda Mars pool cleaner tail scrubber, manufactured from PU

Zodiac Baracuda Mars blowmoulded PE hose floats

Zodiac Baracuda Mars slider manufactured from PVC

PHOTOS: LO

WRIE SHAR

P

The Ezehands grocery bag carry handle which Harrison Designs designed and own the tooling for. The mould pictured was run for the first time during August by Delaplast in Silverton. The Ezehands grocery bag handle is available in either ABS or HDPE

sign) udis (snapp de Jonathan Fund

signs) with n (Harrison De Peter Harriso turer at the lec or ni se , ell Angus Campb rg bu es Johann University of

rdgham, and Rowan Ma Trevor Hollard rg industrial bu es nn ha ity of Jo both Univers the show at d te also exhibi design alumni il and pen and nc pe eir th g – here showin ys paper clip tra




PEOPLE

Many accomplishments of Pieter du Toit

 AUGUST / SEPTEMBER 2013

Lomold man’s determination led to creation of large group PIETER Wouter du Toit was one of the truly exceptional personalities within the plastics industry. His deep-seated passion for the innovation and commercialization of his prized Lomold Group of companies, made him a respectable force throughout the globe and one that will be greatly missed due to his unexpected passing at the age of 57. From the small town of Bronkhorstspruit near Pretoria, it was clear that Du Toit exhibited the keen ability to motivate and undertake big projects. Studying at Potchefstroom University, he was part of the first graduating class in the BSc Computer Science programme. The degree afforded him the opportunity to get involved in the IT sector just as it began to boom locally and he helped build up the SAP business management software brand in South Africa. After he was bought out in 1994, Du Toit settled with his family on a farm just outside Paarl in the Western Cape where he pursued his passion of dairy farming. Not long after, he started getting restless for a greater challenge and founded the Lomold process, a low-pressure injection moulding technology that would become the brainchild of the entire Lomold Group. Du Toit had an extremely resilient nature and always used the phrase: “You can run out of money, but not out of ideas.” His determination and true passion for innovation enabled him to obtain significant milestones along the way to successfully commercializing the Lomold technology, his greatest personal achievement being an amalgamation of all that is listed below: Establishing the Lomotek Polymers compounding business, now one of South Africa’s top polymer compounders, processing about 15,000 tons of material annually Installing and successfully commercial-

Pieter du Toit managed to develop a new technology in a relatively short period

ising two Lomolder machines, one in Huzhou China and the other in Bellville, South Africa Establishing licensing agreements with top tier international companies to use and manufacture long glass fibre products using the Lomold technology Winning the 2010 JEC Innovation Award for the best composite product in the transport category for the high-performance Lomold LFT-PP pallet Winning the 2010 Owens Corning Composite Application Challenge for the collapsible composite box using the Lomold Pallet platform Winning the SAPRO Gold Award for Best 100%-Recyclate product for the recycled PET Lomold pallet

Buying and expanding the Proplas recycling company, turning over 7,000 tons annually Purchasing the Plastamid compounding business in Cape Town and taking over its production site and toll compounding activities Having all four of his sons working under his wing within the companies he built from the ground up. These activities constitute a massive achievement by a single individual and Du Toit was widely admired for his tenacity and ability to make things happen even in the face of extreme adversary. His motto was, “People, Planet, Profit” and he will be missed in the business world.

TASA conference for West Rand

Attendees at the recent Tooling Association of South Africa’s (TASA) conference; Gus Schroeder and Marcus Coetzer of Bohler Steel and Christo Moolman of Hurco South Africa

Peter Black and Vanessa Booyes, both TASA members, and Iain Liddell of Combination Products

The main ‘manne’ – Pieter van R Coetzee (legal advisor), Peter Black (TASA), Henk Snyman (TASA), Je’maine James (National Tooling Initiative Programme), and Neil Sapsford (Gauteng Tooling Initiative)


ON THE MOVE SAPRO’S new committee – Johan Conradie (Myplas), Rudi Johannes (Polymark Recycling), Jaco Breytenbach (Transpaco), Shelley Harris (EnviroServe), Douglas Greig (Tuffy Manufacturing), Annabe Pretorius (Plastix 911), Dewald van Breda (PotchPlastics) and Chandru Wadhwani (Extrupet)

Jam-packed SAPRO AGM SAPRO’S recent AGM in Johannesburg saw members nominate a new committee, find out what is happening in the plastics recycling industry that could impact on business, as well as listen to an update from Johan Pieterse of the Plastics Convertors Association (PCA) about their negotiations with the MEIBC (more of this in our next issue of the magazine). And to add to a jam-packed agenda, attendees were also able to hear an interesting presentation from Charis Lewis of BASF about compatibilisers for recyclate and how it can improve the quality of recyclate.

Charles Muller is to take over as director of the Packaging Council from Andrew Marthinusen in September. But, as one may expect from a man who’s recently escaped from the corporate environment, Charles doesn’t want fulltime any more. None of that says the man, who now sees himself as a consultant. One of his first other consulting assignments will be back in the polymer supply field with Metmar group, where Charles will be involved part time too. He will be assisting Metmar, which recently parted ways with its subsidiary West African Goup, as its realigns its material supply activities across the border.

PHOTOS: LOWRIE SHARP

Ian Edwards has been appointed factory manager at Cibapac’s new plant in Alrode, Gauteng. He was previously at the group’s Cape Town head office plant. The Johannesburg factory is involved in polystyrene foam extrusion and thermoforming. Annabe Pretorius with Charis Lewis, guest speaker from BASF Performance Chemicals

Octogenarian - Oom Hennie Steynberg of Trio Pellets was congratulated by all on his 80th birthday which he celebrated on the same day as the AGM

Plastics & packaging industry measurement needs under the microscope The National Metrology Institute of SA’s (NMISA) recent technical advisory forum on the measurement needs of the plastics and packaging industry was an eye-opener.

Markus Kropp has been appointed as MD BASF Polyurethanes South Africa. Markus has been with BASF group for more than 20 years, in both Asia and Europe where he has focused on operational, strategic and marketing management. Kropp’s appointment will bring knowledge and experience to this young and dynamic organisation in South Africa. He will concentrate on the company’s drive to strengthen and expand its markets in South and Sub-Saharan Africa. Michael Boltau, previously of Lomotech Polymers, has joined ACD Rotoflo, the Kya Sand-based manufacturer of rotational moulding materials.

Dr Eino Vuorinen, organic analysis scientist, with Jayne de Vos, NMISA Director: Chemistry Division. They discussed NMISA’s facilities for testing all chemicals, but specifically the facilities available for testing polymers

Nontete Nhlapo, a scientist with NMISA, with Bernard Reeksting from the Centre for Polymer Technology who presented an “Overview of analytical measurement for contaminants in plastic and packaging” and Annabe Pretorius who heads up the South African Plastics Recyclers Organization (SAPRO), who talked about “Current Import and Export challenges for plastics and packaging”

PHOTOS: LOWRIE SHARP

Lindewe Ntuli of Miller Methods gave a talk on the system being used at Miller Methods with Bernard Cock from TASA who is assisting with the development of the programme

UTP were there in force – Tracey Eliot, Nicole Funk, Kim Eliot-Funk and Grant Hunkin

Paul Prophet, previously of Polipak, has joined Formeset Flexibles in Cape Town. The business, which is part of the Formeet printing organisation, in fact bought the production assets of Polipak last year. Marco Baglione, former CEO of Astrapak group, is travelling in North America on an extended visit. We have asked him to make observations about the plastics packaging sector in the region and advise us on his return near the end of the year. Martin Bensch, who sold his stake in Polisak to Afripack group earlier this year, is still involved with the cement bag manufacturing operation in Brits on a 12-month consultancy basis. Besides that, he is dabbling in the robotics area, as regards the packing of filled cement bags as well as palletizing cement bricks. Richard Mayr has started Karma Sensors, which specialises in process control and automation equipment. Karma Sensors was started in May 2012 and is based in Randburg, Johannesburg. Products include devices and sensors which measure flow, pressure, displacement, level, speed, angle and analytical processes amongst others. Karma also offers project solutions by designing and commissioning electrical and instrumentation control panels. The market focus


PEOPLE

ON THE MOVE is primarily on the food & beverage, chemical, petrochemical, power generation, glass, cement and pulp and paper industries. Karma is a division of Atlas Industrial Systems; it imports its products mostly from Europe and America. Mayr was previously at Swift Heat & Control. Craig Lowe, formerly of Astrapak group, has accepted an offer to join a family packaging group in Bulawayo and is relocating to Zimbabwe. The business is involved in several processes, including injection moulding of furniture and household items and film extrusion/bagmaking; and also supplies customers in Zambia.

New British federation president MIKE Boswell, managing director of Plastribution of England, has been elected president of the British Plastics Federation (BPF), a position he will hold for two years. He was vice-president of the trade body under Philip Watkins, the outgoing president, who is MD of Gabriel-Chemie UK. A long-standing chairman of the BPF’s polymer distributors and compounders group, Boswell has also served on the BPF’s council and its strategy and finance committee. Accompanying Boswell’s election, the BPF published a progress report on the actions arising from Watkins’ discussion document, ‘The UK Plastics Industry: A Strategic Manufacturing Sector’. The report, which has been submitted to the British government, focuses on the issue of skills and training, overseas development, resource management, energy supplies and light-touch legislation, notably around packaging recycling targets.

New investor at Oakville SCHEEPERS Nel has bought a main share in Oakville Products of Somerset East, a manufacturer of educational products, small containers and electrical components. Originally from Somerset East, which is in the Eastern Cape, Nel had been working in Namibia and recently decided to return to his routes and bought the stake in the business from Stephen van Niekerk, who is to remain with the business until 2015. Other news is that Oakville production manager Dick Bradfield retired in about 2011 and is relaxing in the peaceful town.  AUGUST / SEPTEMBER 2013

Industry in Australia faces challenges too Transport DEREK Collinge, formerly with Plastop Transport systems are well developed and Astrapak group in South Africa, emibut pared to the bone. Trucks are loaded, grated to Australia in 2008. For the past driven and unloaded in a controlled and five years he’s been with the Pact group, predictable fashion. Normally there’s only one of the country’s leading manufacturone person per vehicle, and suppliers can ers of PET containers, trays, tubes and track the whereabouts and movement of closure systems as well as drums, pails, their goods at all times. cans and IBCs. We asked Derek for The postal service is extremely efficient. his observations of the industry ‘Down Mail tampering is unheard of and accordUnder’, specifically, if there’s anything we ingly a large amount of sampling to customcan learn from the Aussies. ers is done directly Derek: I’m through the mail. responsible for the Very few sites other than Between the three management and large multinationals use large East coast sales of dispenssecurity services cities, samples ing products from posted in the late Salient Asia-Pacific afternoon are delivered by mid-morning the and Plaspak Sprays. The former is the Australian/NZ licensee to Aptar (Seaquist, following day, often before an external sales person could practically get there. Emsar, Pfeiffer and Valois dispensing system brands) and the latter distributes Other observations Canyon triggers out of Japan. Heat-induction seals for bottles and jars are The FMCG (fast-moving consumer widely used – both for tamper evidence and goods) market in Australia is dominated for freshness. There is less (but growing) by two players, Coles and Woolworths, use of external TE features. IML in both who together have about 80% market extrusion and injection moulding is very share. They in turn compete very hard common. with each other and the pushback and Correct material identification, particularly demands placed on their suppliers have been both ruthless and possibly detrimen- on rigid packaging, is poor, and often absent altogether with very few manufacturers’ tal to local manufacture. logos to be seen. The country’s proximity to south-east Automation Asia allows for quick and direct importation The high cost of labour does result in by distributors and customers, and tends to levels of automation that are higher than in Africa – due to relatively quick payback have a downward effect on pricing. Another trend is brand owners making their own periods. Manufacturing companies here packaging, especially those using singlerun very flat organisational structures – stage PET equipment. certainly, there is no on-site catering staff In a nutshell, whilst the actual design and now even fewer companies have and type of product and production may be receptionists. Many services, such as similar between the two countries, the main cleaning, are outsourced. differences lie in the high cost of labour in The security situation is much more Australia and therefore higher levels of aurelaxed in comparison to SA. Very few tomation, and a high level use of technology sites, other than large multinationals, use and information systems linked into a strong security services, although extensive use is made of technology in the way of CCTV safety and environmental focus. and GPS tracking. Things like fire-drills www.salientap.com.au are practised regularly and pedestrian safety, especially around forklift areas, www.pactgroup.com.au receives the utmost scrutiny and attention. Derek Collinge discussing a dispensing packaging option with a customer


ASSOCIATION NEWS

The future of packaging in SA will challenge all involved Unique opportunities for local packaging industry to meet challenges with innovation hugely and gravure is fighting back. THE Institute of Packaging (SA) WestThere is also a move to inline processern Cape Region’s annual business ing and the future of RFID and printed breakfast in July at the Two Oceans electronics is Aquarium in Cape enormous,” Town was an eye“Consumers today are media Loubser said. opening glimpse savvy, internet proficient into the future of and information saturated. Design trends packaging in SA They will choose the product & consumer and around the packaged in a way that cuts expectations globe. Yve Oosthuizen, through the clutter.” Gill Loubser, owner of Contrast editorial director of Studio, explored what is involved when Packaging and Print Media magazine, it comes to delivering on design trends discussed the factors affecting packand consumer expectations. She tackaging trends today. The progress in led trends that brand owners, designers, lightweighting is one. She pointed out packaging buyers, technologists, printthat in 1979 a 2-litre PET Coke bottle made by Metal Box (ironically) weighed ers, converters and R&D specialists will want to know. 90g – today that same bottle weighs “Packaging design is the path to the just 45g. consumer’s heart and cupboard, even Other factors include legislation (eg. braille must be used on labels in certain though the product is the hero,” she explained. parts of Europe); brand protection (eg. “Consumers today are media savvy, against counterfeiting); added value internet proficient and information (QR codes); traceability and intelligent saturated. They will choose the product packaging. Printing and converting packaged in a way that cuts through the trends are also affecting the way prodclutter. This is the challenge to packagucts are being packaged. “The flexographic industry has grown ing designers – how to stay relevant.” 

Emma Rowberry (chairman of IPSA’s Western Cape Region), with speakers Gerry Kuhn of Dust Watch, Yve Oosthuizen, owner of Contrast Studio and Gareth Pearson of BMI Research

Oosthuizen says that South Africa faces very specific challenges when it comes to packaging, not least the limited buying power of the majority of our population, as well as high illiteracy rates. “However, this is the challenge and presents unique opportunities for the local packaging industry to meet these challenges head on with innovation,” she added.

AUGUST / SEPTEMBER 2013

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New packaging design trends emerging A â&#x20AC;&#x2DC;new business model for goodâ&#x20AC;&#x2122; is one of the trends Oosthuizen described in which consumers look for products that integrate corporate social responsibility. New business model for good â&#x20AC;&#x201C; A good example is Pampers who, working with UNICEF, marketed their range of infant disposal diapers using â&#x20AC;&#x153;1 pack = 1 vaccineâ&#x20AC;? prominently displayed on the packaging. The â&#x20AC;&#x153;1 pack = 1 vaccineâ&#x20AC;? partnership is now in its seventh year. For every specially marked Pampers product sold with the â&#x20AC;&#x153;1 pack = 1 vaccineâ&#x20AC;? logo, Pampers donates the cost of one life-saving tetanus vaccine to help protect mothers and their babies.

Another emerging trend is â&#x20AC;&#x2DC;keep it simpleâ&#x20AC;&#x2122;! Consumers are demanding products packaged in an unambiguous, simple way which use fewer materials and which convey the product info clearly. A great example of this trend at work is the range of kitchen utensils marketed by Zing.

â&#x20AC;&#x2DC;The world goes smallâ&#x20AC;&#x2122; is a trend in which we see consumers buying smaller amounts of their favourite products. An example of this is Unilever who in South East Asia is ahead of the trend selling oneuse sachets of personal care items. Another is Breakthrough Products, Inc., developer of UrgentRx fast-acting over-the-counter ďŹ&#x201A;avoured powder medications. These credit card-sized packs of single-dose powders are produced on a form/ďŹ ll/seal machine by a contract manufacturer. The word goes small â&#x20AC;&#x201C; The UrgentRx packaging was updated to promote simplicity with a clean, modern look to attract the on-the-go OTC consumer while simultaneously focusing on the symptom ďŹ rst, which is how consumers shop OTC. UrgentRx is capturing consumer attention with bold packaging graphics and convenient POP displays that encourage impulse purchases. UrgentRx packets are made from a white stickpack pouch material with DuPont SurlynÂŽ, with a 48-ga overlaminate with permanent adhesive. The package provides child-resistance and is printed in four-colour process with spot colours on a combination ďŹ&#x201A;exographic press.

Keep it simple â&#x20AC;&#x201C; Typically, one does not seek out personality in a pair of tongs, but this is exactly what gives Zing! packaging the upper hand. The line of kitchen utensils presents itself above and beyond the simple and utilitarian expectations. Vibrant blocks of colour make up the tags, boxes and backings of Zing! packaging to ensure that the items really stand out on the shelf. The pieces are personiďŹ ed and accessorised with sociable speech bubbles that express their culinary functions.

AUGUST / SEPTEMBER 2013 

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ASSOCIATION NEWS

‘Using less’ is a trend that sees, for instance, more and more packaging-free grocery stores where environmental concerns and innovation are key. A good example of packaging which addresses this is the sustainable expanded bowl - a sustainable package customised for freeze-dried food - manufactured by Swedish company Innventia.

Using less – Swedish company Innventia say the expanding bowl is made from “special carton bio-based” material. When pouring hot water into the package the mechano-active material will react to the heat and transform from a compressed packaging to a serving bowl.

‘Extreme sensory’ is another trend which packaging designers are using more often to grab consumers’ attention. The trend makes the consumer engage with the product in a way that he or she has never done before. An outstanding example of this is the way Festina watches package their upmarket product in water!

Products that we trust - And last, but not least, are the packaging trends that are led by products that we trust and never question, like Coke! These trusted brands manage to stay relevant and earn consumers’ trust no matter what they do. Coke recently undertook a campaign in Colombia in which it released a limited edition of the original Coke bottle made entirely of ice. The product sold out in record time, even though it cost more than twice the price of a ‘normal’ Coke. Products that we trust – Looking for an icecold Coke on a hot summer’s day? You now have to travel no further than to Colombia (yes, the country). Coca-Cola, in partnership with Ogilvy & Mather Bogota, rolled out a limited-edition bottle made entirely from ice! The new container - only available in Colombia - is shaped like the traditional glass Coke bottle and has the company’s name etched into the frozen water. The bottle is wrapped with a red rubber band, which also doubles as a bracelet that prevents frozen fingers. For the eco-minded, the bottle melts when the drinkers are finished

‘Extreme sensory’ – what better way to showcase that Festina Profundo is a waterproof watch than to create a packaging that lets the watch float in water?

Disturbing trends in pollution patterns Gerry Kuhn of Dust Watch spoke about the worrying trends manifesting in pollution patterns. Kuhn talked about packaging materials and their impact on sustainability and a health environment. He covered air quality, the degradation of packaging materials at a submicronic level and the effect of certain substances on public health. Kuhn said that the packaging industry was the source of many potential pollutants. In precipitant dust monitoring Kuhn said that plastic material fibres Isolated polypropylene fibres found in precipitant dust monitoring

were discovered from time to time in areas well away from factories that could have been the source. “Research over almost 10 years has yielded a rapidly increasing content of artificial fibres. With the increase we have established that most of the fibres are in fact polypropylene and these seemed to emanate mainly from woven fibrous packaging material,” he said. Once synthetic fibres have been in the sun for some time they become brittle and can then easily break and also show a tendency to split. The fibres are normally anything between 10 microns and 25 microns. At this size they do not pose any sort of health risk and if inhaled will be captured in the throat or sinuses. For such a fibre to be a respiratory risk it would need to be below 5 microns in diameter. Kuhn explained that eventually the 10 or 20 micron fibre does split into between 10 and 20 individual fibres. These are brittle enough to break up 

AUGUST / SEPTEMBER 2013

even further, posing a respiratory risk. “However, there is no evidence that polypropylene is a carcinogenic, which is the case with silica dust or asbestos. Even if such a fibre is ingested we have no proof that this could have serious consequences. There has not been any identified instance of lung accumulations,” said Kuhn. Retail trends impacting on packaging Gareth Pearson of BMI Research held the audience’s attention focusing on retail trends that impact packaging in SA and how these affect local packaging and demand. He said 2013 had seen the lowest GDP in SA of 0.9% and that the consumer was under enormous pressure trying to stretch a limited disposal income. “Margin pressure is forcing innovation and making us think about how can we do things more efficiently?” said Pearson.


Factors affecting local packaging manufacture included: Materials – lightweighting, substitution, re-using Production margins – rising energy costs, labour costs, rate of exchange Innovation – companies are ‘outsourcing’ everything but their core competencies, right-sizing packaging, lighter products Substitution – using other substrates for cost and functional properties. Private labels are shifting perceptions Pearson explained that shoppers in Europe are adapting to tough times by remaining price cautious, relying heavily on high promotion activity. Shoppers are still willing to buy value for money; however, non-food categories have become the victim of the tough times. This trend is also manifesting in South Africa. There has also been a growth in the ‘private label’ trend in which private labels are now challenging national manufacturer brands. Where before a ‘private label’ (for instance, Pick ‘n Pay’s house brand) was seen as an economy offering, shoppers are now shifting their perceptions and looking at private labels as a way

of reducing their weekly shop. Interestingly, shoppers focus on the quality of the packaging when evaluating a private label. What’s weighing on retail in SA in 2013? Pearson said that various factors are affecting retail in SA currently. These include price strategies, price sensitivity, price points and the depth and length of promotions. Another factor is right-sizing, i.e. matching the price point with the pack size. Pearson said pack strategy will remain a key consideration. Reduced spend is yet another factor in which retailers are seeing shoppers spending more on food and less on non-food, all the while seeking value and buying on promotion. The huge inflationary pressure on prices is another critical factor. Pearson said that huge energy inflation on manufacture and logistics, fuel inflation and the weakening rand placing additional inflation on imports were issues which directly and indirectly influenced retailers countrywide.

Gerry Kuhn of Dust Watch spoke about the worrying trends manifesting in pollution patterns caused by the packaging industry, while Gill Loubser, editorial director of Packaging and Print Media magazine, discussed the factors affecting packaging trends

IPSA Western Cape golf day THE Institute of Packaging’s golf day in the Western Cape is to be held on 3 October at the Durbanville course. Anyone interested in playing can contact John Fox on 083 383 2129.

www.ipsa.co.za AUGUST / SEPTEMBER 2013 


ASSOCIATION NEWS

Making recycling

a bankable sector 2015 a landmark year – PETCO want to recycle 50% of post-consumer PET collected RUNNING recycling as a business is not a job for wimps! That was made very clear at PETCO’S recent workshops in Cape Town and Johannesburg where the topic of discussion focused on making recycling a bankable sector. It’s a tough sector run by determined individuals – from large enterprises to small family-run businesses – and to survive you need business acumen and drive. The South African recycling industry formally employs close on 10 000 people, with probably twice as many as that involved informally. Cheri Scholtz, CEO of PETCO, said that post-consumer plastic beverage bottle recycling volumes in South Africa grew by 18% year-on-year in 2012. The recycling rate rose from 42% in 2011 to 45% in 2012, whilst the local market consumption of PET grew from 145 000 to 166 000 tons. “By recycling 45% of post-consumer beverage PET, we achieved a full 1% more than what was targeted for 2012,” added Scholtz. Recycling volumes increased from 42 562 tons in 2011 to 50 280 tons of post-consumer PET bottles being recycled in 2012 – a 7718 ton increase. “2015 will be a landmark year for us – we want to recycle 50% of the postconsumer PET collected,” she added The workshop gathered industry professionals to interrogate what it takes to make plastics recycling and collection work. Topics included a reflection on the current market, challenges and opportunities for plastic recyclers and collectors; what the future holds for the recycling and collection sector; and what organisations need to show that they are a good investment. Lauren Basson, from the Western Cape Industrial Symbiosis Programme (WISP), gave an interesting overview of what WISP’s does to assist industry in the Western Cape – an eye-opener for most of the people present.  AUGUST / SEPTEMBER 2013

WISP (www.green-cape.co.za) is waste management company that funded by the Western Cape Governspecializes in recycling and the ment and delivered through. It is a free reduction of waste to landfill. facilitation service Playing devil’s which, simply put, is advocate, Loua resource efficienrens made the cy approach where audience grapple unused or residual with some difresources like mateficult questions rials, energy, water, – do we save assets, logistics and by recycling, will expert knowledge mechanical sortof one company is ing ever be viable used by another. in South Africa, and can curbside Anton Ressel, recycling ever senior consultant be a sustainable at Fetola (www. business? fetola.co.za), small Cheri Scholtz, CEO of PETCO, says Over the years business develop2015 will be a landmark year – by then PETCO want to recycle 50% of the WastePlan has ment specialists, post-consumer PET collected worked on builddiscussed what ing a network companies need to of buyers, both show to be a good locally and internationally. Lourens investment. explains that the process of building According to Ressel, the foundation the network is continuous, because of a profitable and sustainable busithe more buyers that are added to ness has four cornerstones: the network, the greater the chance Build a strong vision of success of being able to sell the useful waste Plan for a long business life material on behalf of their client. Prepare for growth with replicable “The biggest risk to recycling systems in this country is that the markets Create access to resources to which we sell our recycling are (including finance, skills, markets) drying up,” he said. “We need to develop new end markets urgently!” Bertie Lourens, MD of WastePlan he added. (www.wasteplan.co.za) discussed collection models for developing econowww.petco.co.za mies. WastePlan is a national on-site


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ASSOCIATION NEWS

from 16-2 r Septembe

SEPTEMBER is traditionally the month in which South Africans from all walks of life are encouraged to clean-up and recycle where they work, live or play. This year, 16-21 September will once again be â&#x20AC;&#x2DC;Clean-up and Recycle Weekâ&#x20AC;&#x2122; which will culminate in National Recycling Day on 20 September and the 28th International Coastal Clean Up day on Saturday, 21 September. For the past 17 years, Plastics|SA has been the coordinator of Cleanup and Recycling month. What originally started out as a plastics industry drive in 1996, has since developed into a

country wide awareness campaign that enjoys the support and involvement of the National Recycling Forum (NRF) and all of the players in the packaging industry, including the glass, cans and paper converters and recyclers. 28th International Coastal Clean Up Day on 21 September One of the worldâ&#x20AC;&#x2122;s biggest volunteer efforts for ocean health will take place on Saturday 21 September when thousands of South Africans join volunteers around the world to clean up our countryâ&#x20AC;&#x2122;s beaches.

During last yearâ&#x20AC;&#x2122;s International Coastal Cleanup, volunteers picked up more than 4,536 tons of almost every imaginable type of waste along the worldâ&#x20AC;&#x2122;s shorelines. FOR MORE INFORMATION ON CLEAN-UP INITIATIVES, DROP OFF SITES, THE COMPETITION OR HINTS AND TIPS ON HOW TO RECYCLE, VISIT: WWW.PLASTICSINFO.CO.ZA WWW.CLEANUP-SA.CO.ZA WWW.RECYCLINGDAY-SA.CO.ZA WWW.MYWASTE.CO.ZA

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ASSOCIATION NEWS

Polystyrene housing: Recycled PS scrap + patented chemical mix to create solid wall system Government approves construction of a million houses using patented system THE Polystyrene Packaging Council used its AGM hosted at the Two Oceans Aquarium in Cape Town recently to talk about its successes over the past year and inspire industry role players to take part in the association’s numerous projects that have not only developed viable end-markets for recycled polystyrene, but are also touching lives and improving communities around South Africa. One of the most exciting undertakings the PSPC is currently engaged with is a pilot project that has found a viable endmarket for contaminated, coloured and black polystyrene. The PSPC recently partnered with Hennie Snyman of GC Construction and the Mobile Educational and Training Trust (NPO), who have developed a global patented chemical mixture that uses recycled scrap polystyrene to create a solid wall system for use in the construction industry. “The exciting thing here is that this recycled scrap polystyrene includes coloured, black or contaminated polystyrene used in food packaging applications, including fastfood trays, takeaway cups or trays used to package meat and fresh fruit,” explained PSPC director Adri Spangenberg. Spangenberg said that the SABS had subjected the GCC- and METT-patent-

Among the guests at the PSPC function in Cape Town were Mark Boddy of Lanco Wood Moulding, Elma Pollard of ‘The Green Times’, Vanessa Paulse of Mam Sebenzi, Kirsten Barnes of WastePlan (seated in front), Tina Krynauw (also WastePlan), Alison Davidson (City of Cape Town), Ian Clink of Polyoak and Tom McLaughlin of Woolworths

ed chemical mixture to a series of tests, from fire and water-penetration tests to load-bearing, impact and stress tests. The results were “off the charts” and were met with unprecedented success. It was also the first time in history that polystyrene has sustained heat at 1 800˚C. After a two-hour fire test, using 15 000 litres of diesel, the tested panel remained intact. Following the completion of the test, the outer temperature of the polystyrene waste and chemical panel had dropped 21˚C from the start of the test to two hours in furnace. Spangenberg said that GC Construction has received the go-ahead from

the government to contribute to the construction of 1 million houses in Africa using the patented chemical mixture. To meet this demand, three factories will be built in each of South Africa’s nine provinces and use the patented, dry-mix formula (produced at the flagship factory in Pretoria), to manufacture the wall panels. Each 1 200cm x 500cm panel is made from 12kg of recycled polystyrene, waste and chemicals. www.polystyrenepackaging.co.za

Automated collection of recycled polystyrene

The PSPC recently installed software at Doxa Deo School in Hartebeespoort Dam as a pilot phase to coordinate the collection of breadtags in the area and will soon be rolling out the software to the rest of the country during the next six months

THE Polystyrene Council is going high tech with the collection of high impact polystyrene. A new application (app) for SmartPhones and computers, called PolyNet, has been developed specifically for the PSPC to automate the entire process between the project coordinators, collectors and recyclers. “Instead of spending days trying to manually put collectors and recyclers in contact with each other and to arrange collections, the entire process is now automated and simplified,” says Adri Spangenberg, PSPC director. With a click of a mouse, the 600 coordinators of the volunteers who are collecting breadtags for the Breadtags for Wheelchairs project can register on the Council’s website (www. polystyrenepackaging.co.za) when they have

enough breadtags (approximately 680kg), to be collected anywhere in the country. “The software flags a local collector of the material who is instructed to do the collection and even works out the logistics with the recyclers”, Adri explains. “We have recently installed the software at Doxa Deo School in Hartebeespoort Dam as a pilot phase and will soon be rolling out the software to the rest of the country”, Adri says. The same technology will also be employed by the PSPC to coordinate the collection of yoghurt tubs from more than 20 Eco-Schools around the country which gets recycled into Tutu Desks, as well as the contaminated postconsumer polystyrene for use in construction projects.

www.polystyrenepackaging.co.za 


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ASSOCIATION NEWS

SAPPMA raises the bar Pipes association completes third pipe quality survey SAPPMA has just concluded the third round of random sampling of plastic pipes manufactured in South Africa, a process which has led it to ‘up rate’ its membership criteria. In order to qualify for membership of the association, pipe manufacturers will from now need to sign a pledge to allow unannounced factory audits, adhere to SABS minimum standards and all PVC pipe makers will need to manufacture without lead. The goal of the survey is to achieve improved pipe quality. Due to the fact that the plastics piping business is a strategic industry, long-term product quality is fundamental and quality plastic pipe should be good for a minimum period of 50 years according to industry standards. To ensure industry compliance and high standards throughout, SAPPMA launched the first in a series of random sampling exercises at the beginning of 2011, whereby a selection of pipes were randomly obtained from various stocking merchants. How plastic pipes are tested A number of PVC and HDPE pipes, all

bearing the SABS mark of quality, were randomly selected in the market and then tested at an independent certified laboratory, all according to the relevant SANS Standards. According to Jan Venter, chairman of SAPPMA, the results of the tests showed that a considerable percentage of SABS mark-bearing pipes did not entirely conform to the relevant standards. “The SABS mark is supposed to give consumers and end-users peace of mind that a product has passed performance and quality assurance tests stipulated in a standard or regulation, or that the product complies to a national and international standard or regulation governing quality and minimum performance requirements”, Venter explained. However, due to growing economic pressures, it is easy for a manufacturer to look for ways in which to cut costs, which often impacts negatively on product quality. “It is important too for SAPPMA to be seen as not working against the SABS, but as an association that is strongly supporting them as Custodian of the National Product Standards,” Venter

Pipes VII on 10 September SAPPMA will be building further on momentum gathered over the last few years when it hosts the seventh edition of its Pipes conference in Dr Roelof Botha, September. economist, commentaPipes VII is tor … and humourist, is the keynote speaker to take place at this year’s Pipes VII on Tuesday, 10 conference September at the Bytes Conference Centre in Midrand. Over 200 delegates attended the event last year, a good result for SAPPMA after it marketed itself more actively in the engineering and munici

AUGUST / SEPTEMBER 2013

pal sectors. According to SAPPMA chairman Jan Venter, the annual conference has gained the reputation for being the plastic pipe industry event of the year. Besides keynote speaker Dr Roelof Botha, the economist and commentator … and humourist, this year’s event will consist of two parallel sessions which run concurrently. • The cost for the full-day conference is R900 for SAPPMA and IFPA members and R1700 for non-members. This fee has not been increased from last year and includes lunch, coffee and tea breaks and information packs. Registration forms are available at

www.sappma.co.za

says. “It is our vision to create absolute quality, trust and integrity throughout the value chain of the Southern African plastics pipe industry. To this end, SAPPMA continues to work very closely with the SABS in a joint effort to weed out inferior quality plastic piping systems.” Raising the bar to become a member of SAPPMA Although the quality of pipes manufactured by SAPPMA members were generally superior to those manufactured by non-members, the association felt it necessary to develop a number of additional requirements that need to be met before pipe manufacturers would be allowed to obtain and use the SAPPMA mark of approval. These include: the manufacturer’s products must be SABS approved and bear the SABS mark; the manufacturer must be listed under the ISO 9001 scheme, or working towards it (in the latter case SAPPMA will conduct a full systems audit prior to accepting the member);

Revised technical manual SAPPMA has released its revised 20132014 Technical Manual. The annually updated manual provides basic, relevant and updated information to engineers when they select and specify the plastic pipes that are to be used in water supply and waste-water disposal applications. The 2013-2014 edition is influenced by some of the latest international trends and developments coming out of the overseas plastic piping industry aimed at aimed at quicker and safer installations, reducing manufacturing costs, reducing down time and improving overall efficiency. It also includes sections on HDPE fabricated fittings as well as the jointing of HDPE. Copies of the publication will be made available to design and civil engineers via SAICE or can be purchased directly from SAPPMA for R200.00 per copy.

• FOR MORE INFORMATION, CONTACT LOUISE MULLER AT ADMIN@SAPPMA.CO.ZA


the manufacturer’s CEO must sign a code of conduct and letter of undertaking, outlining certain matters related to quality. This document must be refreshed annually before Membership Certificate is issued. regular, unannounced factory audits will be carried out, whereby pipe samples are to be taken and tested at an independent laboratory; PVC pipe must be manufactured without lead or any other heavy metal stabilizers; additional internal standards are continuously developed and applied to further raise the product standard of member companies. To improve on the current differentiation between the plastic pipes manufactured by members and non-members, the SAPPMA board has decided to implement additional disciplinary steps against members whose products repeatedly do not

SAPPMA AGM on 20 August

To ensure industry compliance and high standards, SAPPMA launched the first in a series of random sampling exercises at the beginning of 2011, whereby a selection of PVC and HDPE pipes were randomly obtained from various stocking merchants

conform to standards. The process for the fourth survey has already begun. “In the interest of the consumer and the long-term integrity of the infrastructure, SAPPMA will continue with these market surveys. We are confident that independent tests such as these will increase the public’s awareness of quality issues, which will ultimately raise the level of responsibility of manufacturers,” added Venter.

SAPPMA will be hosting its 9th AGM on 20 August at the Bytes Conference Centre in Midrand. Dr Taddy Blecher, Chairperson of the SA National Government task team on Entrepreneurship, Education and Job Creation, and CEO of the Maharishi Institute and the Community and Individual Development Association, has been invited as keynote speaker. Dr Blecher is considered to be a pioneer of the free tertiary education movement in South Africa, and has helped to create six free access institutions of higher learning. He was recipient of the World Economic Forum ‘Global Leader of Tomorrow’ award in 2002, and was a World Economic Forum ‘Young Global Leader of the World’ in 2005. The annual SAPPMA merit award winners will also be announced, followed by a lunch.

• TO RSVP OR FOR MORE INFORMATION, EMAIL LOUISE MULLER AT ADMIN@SAPPMA.CO.ZA OR CALL (011) 314 4021. www.sappma.co.za

www.sappma.co.za AUGUST / SEPTEMBER 2013 

Reg No 80/05518/07

POLYSTYRENE: GPPS/EPS/HIPS – ABS – SAN – ACRYLIC – ACETAL – NYLON – PBT – PC – SBC – HDPE – LLDPE – EVA – PP

HIPS – GPPS – EPS – FOR ALL APPLICATIONS DENKA POLYLAC INJECTION MOULDING & SHEET EXTRUSION KIBILAC KIBISAN

PS – ABS – ACRYLIC – PC NYLON – PP – HDPE – LDPE

PA6/PA66/PA12 – INJECTION MOULDING – EXTRUSION KOCETAL WONDERLITE

(VARIOUS VA CONTENTS) KIBITON

WONDERLOY ACRYREX ACRYSTEX SPESIN

Delene Williams,


ASSOCIATION NEWS

Malaysian toolmakers look to SA toolmakers for JVs

PHOTO: LOWRIE SHARP

Partnering with Malaysian toolmakers will help SA grow local industry RECOGNISING the potential for toolmaking activities, especially seeing that the South African motor industry wants to manufacture one million vehicles by 2020 and to increase the local content to 70% from the current 35%, Malaysian toolmakers have identified South Africa as a country of opportunities to grow the local toolmaking industry. At the recent Tooling Association of South Africa (TASA) Conference, held during the Afrimold exhibition, Amrizal Majid, CEO of Malaysian toolmaking company, Miyazu, gave a presentation

on the development of the Malaysian toolmaking industry from 1980 to the present. One-stop-shop to OEMs The presentation inspired the audience as it gave an idea of how Malaysian toolmakers progressed from supplying small tools to being able to produce complete vehicles with local tooling. This learning curve has helped them to develop a strong understanding Members of the Malaysian delegation of toolmakers who attended the TASA Conference, Asyraf Abdul Rahman (Autokeen), Neil Sapsford (Gauteng Tooling Initiative project manager), Nizar Talib (Hicom Diecasting), Henk Snyman (Gauteng Tooling Initiative), Amrizal Abdul Majid (CEO of Miyazut), Masri Idris (MIDA) (behind), Idris Musa (Autokeen), Abdul Razak Ismail, Hasry Harun (MIGHT) and Sureiya Adam (DENEL)

 AUGUST / SEPTEMBER 2013

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Gator Products Energy Efficiency

AC Motor Control & Automation Products

of how to project manage all the tools needed for a full vehicle. This has enabled Miyazu to become a one-stop-shop to OEMs, an area where South African toolmakers are at a distinct disadvantage. By partnering with Malaysian toolmaking companies, South African toolmakers can expect to gain an understanding of how to grow the toolmaking fraternity in a developing country. And since Malaysian toolmaking companies supply products into Europe, the United States and South America, South African toolmakers who partner with these companies will also gain immediate access to international markets. Malaysian toolmaking companies such as Miyazu consider it a positive factor that there are export credits available on the exporting of tools from South Africa and that tools can be exported into the USA and Europe tax-free. Furthermore, South Africa’s positioning in the same time zone as Europe, the good banking system and the fact that European designed vehicles are being manufactured in South Africa for export worldwide will also provide a distinct advantage to the Malaysian/South African produced tools. • SOUTH AFRICAN TOOLMAKING COMPANIES INTERESTED IN EXPLORING A POSSIBLE JOINT VENTURE WITH MALAYSIAN COUNTERPARTS ARE ENCOURAGED TO CONTACT HENK SNYMAN ON (012) 643 1285 OR EMAIL ON HENKS@ TASAWEB.CO.ZA TO FIND OUT MORE ABOUT THIS OPPORTUNITY.


Southern African Vinyls Association (SAVA)

PVC in

energy efficient buildings PVC a responsible, sustainable material with wide areas of application

Setting the record straight While some vinyl products such as siding and flooring have recently been criticized by builders or architects questioning the wisdom of specifying materials made from PVC, SAVA will be using this year’s GBCSA theme of ‘ReWire’ to set the record straight and assist these specifiers to make intelligent choices. “We want to change people’s negative perceptions about PVC by educating visitors to the convention and exhibition about the energy efficiency of vinyls in building and construction,” Delanie says. PVC has been in wide use for more than 50 years. It meets international standards for safety and health for the applications for which it is used, as well as the SANS 10400 guidelines for energy efficient buildings as prescribed by the SABS. SAVA was recently instrumental in the Green Building Council of SA’s decision to withdraw the Mat-7 PVC

Minimisation credit from the Green Star SA rating system which encouraged its replacement with an alternative product. According to Delanie, this was a major step forward in SAVA efforts to promote PVC as a responsible and sustainable material with wide areas of application. Product stewardship issues cornerstone of SAVA “Our members have all voluntarily committed themselves to the industry’s Product Stewardship Programme (PSP). This forms the cornerstone of SAVA efforts as we aim to raise awareness of the good qualities of PVC by assisting its members, relevant authorities and experts to understand, characterize and address product stewardship issues association with the life cycle of PVC products,” she explains. The PSP consists of five fundamental key areas: The responsible and sustainable use of additives, including (but not limited to) stabilizers, plasticizers, pigments and Bisphenol A. The responsible and sustainable vinyl recycling program that quantifies the opportunity for recycling in post-production and post-consumer waste and sets realistic and sustainable goals. Open and effective communication with industry role players, the public and government in order to ensure that PVC is used effectively and cost effectively. Ensuring the industry’s health through product, market and application opportunities, thereby improving human capital and overall growth, prosperity and sustainability of the vinyl industry. Ensuring a fully functional industry initiative that adds value to both members and the industry by growing a sustainable membership base with an effective marketing plan. Thanks to its light weight, high strength-to-weight ratio, corrosion AUGUST / SEPTEMBER 2013 

Chairman Gary van Eck p. 011 552 6200 | c. 082 882 3333 | e. gary@sunace.co.za www.savinyls.co.za

resistance, durability, low cost, and easy installation, PVC hold various benefits for the building and construction industry. “The use of PVC in windows profile, for example, results in lower maintenance requirements – it does not need to be painted or stained as is the case with wood. From an environmental standpoint, vinyl offers advantages of avoided air pollution that results from painting or staining wood and hardboard siding. It is less energy intensive than aluminum, can be recycled and offers a durability that is hard to match by alternative materials”, Delanie concludes. www.savinyls.co.za

ASSOCIATION NEWS

THE Southern African Vinyls Association (SAVA) will be using its presence at this year’s annual Green Building Expo to promote and encourage the use of PVC in energy efficient buildings. The sixth annual Green Building Council SA Convention and Exhibition will take place at the CTICC in Cape Town from 16-18 October. PVC was first produced in a laboratory in 1872. It began to be produced commercially in the 1930s, when techniques for mixing it with plasticizers became known and PVC emerged as a substitute for rubber. During World War II, German scientists developed PVC pipe for water supply systems when material shortages limited conventional pipe supplies. “Today, PVC is by far the most common plastic used in the building and construction industries and has a wide range of applications, ranging from use in pipes to wire sheathing, flooring and weather-stripping”, says SAVA CEO, Delanie Bezuidenhout.

CEO Delanie Bezuidenhout c. 082 444 6866 | e. delanie@savinyls.co.za


ASSOCIATION NEWS

Doors open for young students after NMMU studies ing and research’. He outlined what polymer science courses are offered, and did so with tangible enthusiasm. After departing from universities or colleges, students tend to move on from the pure chemistry – although understanding of the formulae and trends are hopefully never forgotten – and rather focus on practical production outcomes. Students can enroll for a national diploma in polymer technology and part of the process involves a one year in-service training period with a company in the polymer field, prior to graduation. The University also offers a tailormade course on rubber technology, specifically designed for application in the rubber component manufacturing sector. The course is presented on a one-day-a-week basis for six months and, while the course has been strong-

FANUS Gerber is a man who takes training and tuition very seriously, and we in the polymers business need to be grateful that we have individuals who are so committed to this cause. Young individuals (and some not so young) need to undertake their studies with enthusiasm if they are to make a genuine contribution in the industry and, possibly even more importantly, create career paths for themselves. With this in mind, Fanus – of the Nelson Mandela Metropolitan University in Port Elizabeth – headed for KZN recently and gave a presentation about the courses offered at NMMU to a gathering of the IOM³ at the Victoria Country Club in Pietermaritzburg. Fanus is a senior lecturer in the chemistry department of the Faculty of Science at NMMU. His topic on the occasion was ‘The South African Polymer industry: train-

Fanus Gerber with two recent graduates from NMMU, Monwabisi Ncayiyana and Ndili Ntloko, who completed their in-service training at Aberdare Cables in Maritzburg and who are now employed by the Powertech group company

Fanus Gerber and Janine Kruger of Plastichem, which sponsored the function

ly supported by the Eastern Cape rubber industry, students from far afield have also attended. • THE EVENING WAS SPONSORED BY PLASTICHEM AND THE KWAZULU SCTION OF THE IOM³.

 AUGUST / SEPTEMBER 2013

Dave Moore: 083 675 8325 Email: mouldbasesa@gmail.com OFFICIAL DISTRIBUTOR FOR: LKM Wide range of mould bases and mould components in stock for immediate delivery Yoke Industrial Specialised lifting points for the moulding industry Suresee Vision systems for mould inspection and protection Forwell Tech Hydraulic quick mould change system Maxmagnet Magnetic platens Topstar Ancillaries for the injection moulding industry including robots, loaders, dryers, mould temp controllers, centralised material feed systems and more. Stock arriving in the last week of July. Dave Moore: 083 675 8325 | Fax: 086 540 0908 | Email: mouldbasesa@gmail.com | Physical address: Unit 12 Oldfield Business Park, Haworth Road, Mkondeni, Pietermaritzburg | KZN, Eastern & Western Cape – Garth Maccallum: 074 589 3357 or sales@mouldbasesa.co.za Official South African Representative for the LUNG KEE GROUP

www.mouldbasesa.co.za


For more information, or to register, contact: Anlé van Niekerk, phone: +27 82 782 0413, or email info@armsa.co.za or Wayne Wiid, phone +27 82 772 7369 or email: chairman@armsa.co.za

ARMSA’S Rotation 2013 conference will be held from 4-5 September, this year at the Kloofzicht Lodge in the foothills of the Zwartkops Mountains in the Cradle of Humankind. Guest speakers include: Ravi Mehra, chairman of ARMO and founding chairman of StAR

Dr Marek Szostak, chairman of the Polish Rotational Moulding Association Dr Taddy Blecher the CEO of the Maharishi Institute, CEO of the Community & Individual Development Association, executive chairman of Invincible Outsourcing

and chairman of the SA National Government task team on entrepreneurship. Other topics to be covered include new materials for rotational moulding, rotational moulding ‘problem solving’, cost reduction programmes, as well as an industry update.

Who will be this year’s Packaging Achiever NOMINATIONS for the Packaging Council of South Africa’s ‘Packaging Achiever Award’ for 2013 closed on 15 August. This Award is made every second year and is the highest accolade given to an individual by the South African Packaging Industry. Criteria for the award include: The actions of the Packaging Achiever must have had a positive national influence on the South African packaging industry; An added advantage would be if they

The Award was first made to David Brown in 1989 and has been conferred on the following 11 individuals since: • 1991 Piet Neethling • 1993 Peter Campbell • 1995 Gill Loubser • 1997 Trevor Evans • 1999 Di van Breda • 2001 Derek Minnie • 2003 Andrew Marthinusen • 2005 Ray Crewe-Brown • 2007 Keith Pearson • 2009 Horst Sass • 2011 Mike Arnold The winner will be announced at the IPSA Gold Pack Awards evening in Johannesburg on Tuesday 22 October.

have represented the SA Packaging Industry on an international level; The award is not limited to CEOs of the major organisations, or people who have been in the packaging industry for a very long time, but rather to those who by their passion and behaviour have made a difference to packaging; It is also not limited to PACSA members, but can be bestowed on anybody at any level of the packaging chain in recognition of outstanding service to the industry.

AUGUST / SEPTEMBER 2013 

VIRGIN POLYMERS & RECYCLED MATERIAL • HDPE • LDPE • LLDPE • PP • PVC • EVA • PET • Natural & Synthetic Rubber • • • •

Masterbatch Additives & Inks Purging Compounds Chemicals & Solvents

DISTRIBUTION AGENT INTO AFRICA Contact: Tel: +27 11 803 0333 • Fax: +27 11 803 0332 • Cell: 0082 604 5926 • Email: safrique@safrique.com 50 Wessels Road, Rivonia, Gauteng, South Africa


ASSOCIATION NEWS

13-year-old astounds KZN members with her knowledge of plastics

Chairman’s awards – Douw Steyn and Jacques Lightfoot of PlasticsSA received National Chairman’s Awards from PISA national chairman Martin Wells (centre) at Afrimold in June. These gentlemen have made major and on-going contributions to Plastics|SA’s environmental work around the country over an extended period. In fact, they are so involved that one forgets that a lot of their work is virtually on a voluntary basis. The awards included a small cash donation – Well done guys, and well deserved!

Plastics Institute of Southern Africa National Chairman Martin Wells p. 021 712 1408 c. 082 822 8115 e. martin@summitpub.co.za National Vice-Chairman Alain Berichon p. 031 461 2990 c. 082 888 2429 e. alain@neupack.co.za National Secretary David Rule p. 011 452 6940 c. 082 552 0726 e. david@plasticolors.co.za

KwaZulu-Natal Garth Taylor c. 084 924 4551 e. garth@pcasa.co.za Vice-chairman Clement Makhoro p. 031 702 7222 e. Clement.Makhoro@plasticssa.co.za Northern Bob Bond p. 012 799 9260 c. 083 227 0797 e. BondRJ@tut.ac.za Western Cape TBA www.pisa.org.za

IT’S time for the fourth annual Best Recycled Product Competition, organised by the South African Plastics Recyclers Organization (SAPRO), with the support of Plastics|SA. The competition closes on 26 August so there’s not much time. Each year this competition aims to acknowledge products that are made from recycled materials, thereby encouraging brand owners and industrial designers to consider recycled plastics as a material of choice. The competition invites entrants in four product categories: Products made from 100% recyclate

PISA’S KZN region were brave when they invited 13-year-old Elissa David to address its AGM held at the German Club in Westville in June. And everyone present was astounded and pleasantly surprised when Elissa presented her topic on how her interest in plastics began and what she is doing with her knowledge today. One of her latest ‘inventions’ are balls, which she has manufactured from Borax* and other materials. Elissa has won various awards for her achievements since 2007, but it was in 2011 that she really began to focus on plastics, presenting her first paper on how to manufacture the balls at the Eskom Expo for Young Scientists. She was awarded a gold medal for her work. In 2012 she once again won several awards, with her main achievement being a paper on BPA (Bisphenol A), which she entitled ‘BPA: The Gender Bender’. Elissa, then a Grade 6 learner, was able to back all her findings with research and 147 questionnaires she had collected. Kevin Govender from GPS Plastics has been mentoring Elissa these past few months. Her next project is on biodegradable plastics and recycling. • CONTACT GARTH TAYLOR AT GARTHTAYLOR42@GMAIL.COM IF YOU WOULD LIKE A COPY OF ‘THE GENDER BENDER’ PAPER.

Products containing a percentage postconsumer recyclate Products made from a mixture of materials Novel and artistic products - i.e. articles made from discarded plastics products. Entries are judged on a number of criteria: Life expectancy of product Sustainability of product, i.e. long-term demand and market acceptance of product (will it still sell in 5 years’ time?) Measures taken to ensure product consistency and customer satisfaction

Elissa David received a gift voucher from PISA KZN chairman Garth Taylor following her impressive presentation * Borax, also known as sodium borate, sodium tetraborate, or disodium tetraborate, is an important boron compound, a mineral, and a salt of boric acid. Powdered borax is white, consisting of soft colourless crystals that dissolve easily in water. Borax has a wide variety of uses. It is a component of many detergents, cosmetics, and enamel glazes. It is also used to make buffer solutions in biochemistry, as a fire retardant, as an anti-fungal compound for fiberglass, as a flux in metallurgy, neutron-capture shields for radioactive sources, a texturing agent in cooking, and as a precursor for other boron compounds.

despite recycled material content Tonnage (potential tonnages) converted Environmental contribution of product in market place Technical achievements in manufacturing excellence to overcome recycled material challenges Replacement of alternative materials Wow! Factor Last year’s judges were thrilled with both the quality and quantity of the entries received that year, proving that the plastics recycling industry is growing in size, sophistication and value. www.sapro.biz

2012 Silver award winner – The Tabitha Star Light entered by the Libere Foundation. This stunning light is made from PET beverage bottles



2012 Gold award winner – The rPET Lomold pallet by Lomold

2012 Overall winner – Lasher Tools’ Ecobarrow


Record field of 168 at KZN golf day Biggest field at PISA golf day, ever WITH a field of 168, the PISA KZN golf day at Royal Durban on 12 July was probably the biggest PISA golf day ever! The organisers were very dubious that the day would go ahead at all, as the July Handicap used the course for the ‘tent town’ the weekend before, and it had rained on the Thursday and Friday before the July. The course was damaged but the Royal Durban management made sure that the course was playable, well, almost. So the event went ahead in clear skies, fortunately, with the main sponsor for the day, Hosaf, having sponsored the stylishly designed golf shirts. Hosaf was represented by MD Peter White and two of his team, Tsepiso and Rani, who helped out with the organisation of the day. A big thank you to the Hosaf team. The oldest player was a 71-year-old (Garth Taylor) and the youngest was Kavishen Govender, just 12 – and the latter was among the winners! Every player who finished got a prize, and a new prize was introduced – donated by Sangio Pipes The GPS fourball – consisting of Donald Govender, Tony Paddayachee, Kevin Govender and Deva Govender – ran away with it and won the day with 111 points. Here we see them with Peter White (second from right) of Hosaf, the main sponsor, and the KZN floating trophy, a beautiful wood carving of a rhino … well done guys!

in memory of Gary Warren, who passed away whilst riding the Argus Cycle tour in March. That was for the best individual player of the day, who on this occasion was Chris Coetzee with 47 points. Sangio also sponsored the halfway house, making sure everyone was well fed. The first prize was won by GPS Plastics, whose Kevin Govender, Tony Paddayachee, Donald Govender and Deva Naidoo came in with 111 points. GPS has sponsored the KZN day on two previous occasions, so they perhaps deserved to take it this year – well done guys. The competition was an Alliance, with two scores to count on the par 4’s and 5’s and all four scores counting on the par 3’s. The Rhino Army was present as the beneficiary and raffled a prize of a week’s time share at one of the country’s top golf resorts, and the winner was Bruce Naidu of Skyland Masterbatch. That was just rewards as Skyland had in fact donated the 12 top prizes for the day. The organising committee decided to

Runners-up – Team Mercury were in good form and ended in second place. Conrad Pillay, Jaco van Rensberg and Hendrik van Rensberg were solid on the day; here we see them with Peter White. The fourth player was Clinton van Rensburg, not in the photo – and, no, the little chap did not play!

make the Rhino Amy the beneficiary for this day, and Rhino Army fundraiser Cara Ridl managed to raise quite a bit through the lucky draw competition – virtually everyone bought a ticket. All in all, it was a great day!

Lucky draw – Bruce Naidu of Skyland Masterbatch, which sponsored 12 team prizes, had a good day too, winning the Rhino Army lucky draw competition. Here we see him with Garth Taylor, organiser and oldest player on the day!

The President Plastics fourball were third on the day. Here we see Bobby Pillay of BNR, the Durban agent for President of Newcastle, with Dhevan Govender, Thaveshan Govender, Selvan Padayachee, Shiven Govender and 12-year-old Kavishen Govender

Rhino Army – The day was given additional meaning by the collection for the Rhino Army, and many of those present made donations. Rhino Army fundraiser Cara Ridl was able to get almost everyone to donate!

Global colloquium on recycling & waste management in Cape Town PETCO will host a delegation of the European Association of Plastics Recycling and Recovery Organisation (EPRO) when they hold their first AGM on African soil in Cape Town on 20 November. To maximize the opportunity to learn from each other’s best practices about waste management, recycling, green economy and packaging initiatives, a global colloquium

with leaders in the recycling and waste management industries will take place the following day on 21 November. The colloquium, ‘Global partnerships for a sustainable recycling sector’, will see 15 international speakers paired with 15 local industry leaders sharing their views on the water management and recycling economy, trends, legislative tools,

technical innovation and more. PETCO invites all industry partners to attend the full-day conference at The Pavilion, V&A Waterfront, Cape Town. • FOR MORE INFO, VISIT WWW.PETCO.CO.ZA/EPROCONFERENCE AUGUST / SEPTEMBER 2013 


PRODUCTS

Mpact plastic jumbo bins

offer financial benefits A study conducted for a fruit farm in the GrabouwElgin area revealed that cost savings estimated at R138.69 per bin per annum were achieved by comparison with traditional wooden bins, with a payback period of three years

INNOVATION in the design and science behind packaging yields significant benefits in terms of cost savings, efficiency, brand equity and recognition, says Bruce Strong, CEO of Mpact, the largest provider of plastic and corrugated packaging solutions to the South African agricultural sector. Packaging must have vertical strength when stacked to be able to withstand up to 1 500kg on the bottom layer. This is where the science behind packaging becomes critical; it needs to be robust enough for stacking and light enough to remain economical. Transport is a large cost for the agriculture sector and through innovation in light-weighting. The use of plastic ‘Jumbo’ bins offers significant financial benefits in the agriculture industry. The PP bins are injection moulded by Mpact Plastic Containers at Atlantis in the Western Cape. A

New railway seating solution SABIC Innovative Plastics business recently showcased its tough, new seat back shells and side panels for first-class railcars for GRAMMER Railway Interior GmbH that comply with Europe’s upcoming CEN/TS 45445 harmonized standard for fire safety. Using SABIC’s new Lexan FST (flame-smoke-toxicity) copolymer – which meets requirements for the highest hazard level (HL3) under CEN/TS 45445-2 – SABIC worked with GRAMMER on their development of the seating components two years ahead of the standard’s implementation. Importantly, the Lexan FST copolymer can be moulded into GRAMMER’s existing tooling, avoiding significant capital costs and provides exceptionally high flow, which enables large parts to be injection moulded with high-quality aesthetics. The upcoming implementation of the CEN/TS 45445 standard in Europe in 2015 raised the possibility that seating manufacturers might have to stop using thermoplastics unless a  AUGUST / SEPTEMBER 2013

compliant material could be identified. GRAMMER approached SABIC for assistance with this dilemma. The two companies worked together to find a solution that would not only provide the required compliance but also would allow GRAMMER to retain its existing designs and tooling. According to the certificate from the Currenta Institute, which performed independent testing, the Lexan FST

grade achieved the HL3 hazard level, the most challenging to achieve under the new norm. This copolymer features sustainable flame-retardant technology and provides excellent low heat release performance. It is a high-flow material suitable for large, injection-moulded parts such as GRAMMER’s seat back shells, and can be custom coloured using the services of SABIC’s world-class Color Xpress capabilities.

SABIC’s Innovative Plastics business’ tough, new seat back shells and side panels for GRAMMER Railway Interior GmbH

www.sabic-ip.com


Parmalat innovates study conducted for a fruit farm in the Grabouw-Elgin area revealed that cost savings estimated at R138.69 per bin per annum were achieved by comparison with traditional wooden bins, with a payback period of three years. The plastic bins weigh 45% less than the wooden bins, which enables quicker and safer handling and stacking. Bins can be vertically stacked up to eight units high because of a positive interlocking mechanism, which is safer than wooden bin and also means that more produce can be transported. The inbuilt ventilation also reduces cooling time and saves energy, and a clean, non-porous surface provides a hygienic, bacteria-free environment. Ultimately this means that the produce arrives at its destination in a better condition when compared to wooden bins.

through design PARMALAT presto™ the anywhere, anytime squeezable snack uses patented Crushpak™ technology and engages with consumers on a functional level. The packaging is unique to South Africa and exclusive to Parmalat (Pty) Ltd. This pack allows consumers to enjoy yoghurt in three easy steps, simply open, squeeze and enjoy! As the cup is squeezed the yoghurt eases up and can be eaten without a spoon and without any spilling. Parmalat presto™ packaging has increased strength, and uses less material and processing functions than conventional yoghurt packs, translating into a lower carbon footprint. www.parmalat.co.za

www.mpact.co.za

improved stress crack resistance RADEL® polyphenylsulfone (PPSU) resin from Solvay Specialty Polymers delivers high strength, toughness and high stress crack resistance in a new high-pressure impeller developed by Chinese company M.U.S. International. The high-performance thermoplastic replaces competitive materials such as modified polyphenylene ethers (PPE), offering improved stress crack performance. The injection moulded impellers range in size from 34mm to 48mm diameters. Radel PPSU is a super-tough thermoplastic with high heat resistance, exceptional hydrolytic stability, and excellent chemical resistance. It can withstand over 1000 cycles of steam sterilization without significant loss of properties. It is inherently flame retardant and is resistant to bases and other chemicals. www.solvay.com

www.mus-intl.com

PET bottle

PRODUCTS

PPSU delivers

Tea leaf sculpted CRYSTAL Geyser Water Co., Calistoga, Calif., has introduced its award-winning Tejava® Premium Iced Tea in eye-catching, elegant 18oz PET bottles from Amcor Rigid Plastics, the world’s leading producer of PET packaging. A cross-functional team from Crystal Geyser and Amcor achieved a major technical feat by applying Amcor’s vast industry experience along with advanced software programs to develop the first-of-its-kind handsculpted PET hot fill bottle. This innovative package design integrates a life size tea leaf motif with threedimensional qualities into the bottle’s shape. This ‘organic element’ design had never been done before but Amcor was able to deploy the right tools, great talent, and the entire team to make it happen. While the focus was on maximizing the design, Amcor also ensured that the bottle met its performance requirements. Amcor used its PowerFlex technology which features a patented panel-less design. Amcor’s structural design eliminates the panels, and unlike competitive containers, provides the freedom to create various designs along the walls. Amcor uses design and manufacturing techniques to create a patented bottle that absorbs vacuum via a specially designed base. A unique diaphragm within the base draws upward as the liquid cools. It has the geometric characteristics to enable the inverted cone-shaped diaphragm to deflect upward as the vacuum is created. www.amcor.com

www.crystalgeyser.com




PRODUCTS

PRODUCTS

Plastic components

Marley Launches

for cutting tools

REDI uPVC fittings in SA

GREINER Assistec displays its technological diversity in the production of water sets for Makita and Dolmar cutting tools. From concept to serial production, Greiner Assistec supports the Makita Group during the development of its water sets. The plastic components designed for the cutting tools need to fulfill an array of specific requirements. A unique and highly functional solution was implemented using a variety of technological methods. During practical use, water sets are exposed to heavy loads. Therefore, the deflection temperature needs to be as high as 200º C under load (1.8 MPa). In addition, the water sets need to contain flying sparks. And another demand is water tightness along with the relevant throughput, and this is provided by the specialized inner geometry of the plastic parts. This challenge in regards to geometry is overcome by Greiner Assistec with the use of GIT (Gas Injection Technology), an injectionmoulding technique that is particularly suitable for thick-walled components. Crosslinking (electron radiation) is used to modify the plastic parts to resist high temperature loads. At the Greiner Assistec facility, these plastic parts with their enhanced material properties are mounted on the water sets.

MARLEY Infrastructure, a division of Marley Pipe Systems, has added a new range of PVC injection moulded sewer fittings to its extensive selection of pipes, fittings and accessories. Secure, reliable and efficient, REDI provides easy-to-install PVC fittings solutions aimed at building long-lasting networks in municipalities. REDI fittings are injection moulded, offering superior quality in comparison to fabricated alternatives, providing a complete PVC underground drainage solution suitable for use in a variety of applications, including reticulation mains, industrial process pipelines, effluent pipelines and slurry pipelines. The high strength to weight ratio together with exceptional resistance to corrosion or chemical attack makes these fittings ideal for major infrastructure applications. The light weight of the fittings ensures ease of handling and reduces

laying costs while the dual hardness rubber ring improves reliability and reduces the effort required in jointing. In addition to excellent internal/external corrosion resistance, REDI fittings are also electrically non-conducive, making them resistant to electrolytic corrosion, allowing for a longer service life overall. REDI fittings are manufactured according to EN1452-2 standards, complying with the requirements as set out by the European Standard Institute, and are fully compatible with SABS 791 (Solid-Wall) and SABS 1601 (Foam-Wall PVC pipes). The REDI range of uPVC fittings are now available from Marley in sizes from 160mm up to 250mm, and includes taper pipes, junctions, adaptors, sockets and more. www.marleypipesystems.co.za

Beverages crate is

www.haidlmair.com

product of the year A PA6 GF30 plus an additive for process irradiation was used for the production of the housings and other components in these

www.greiner-gpi.com www.greiner-assistec.com

PET crates for 6 x 1.5 litres of reusable bottles made in Adelholzen won the prestigious ‘Product of the Year’ award of the German Association of Industries pro-K semi-finished products and consumer products made of plastics in the category of Storage & Transport Systems. The machinery and tools for the production of the beverage crates came from Haidlmair, the machine tool construction company. A special plastic injection-moulding technology was used to design the unusual label on the crates - a relief-like mountain structure. The label runs apparently seamlessly all around the crate and acts like a closed label. The jury awarding the prize was delighted by the product and said: “The PET crate of Adelholzen is the 3.0 crate of bottles: All-round print plus the 3-D effect. It is the future of brand communication in the segment of bottle crates.” 

AUGUST / SEPTEMBER 2013


K2013

New & surprising developments

at K2013 Reduced sales activity post-2009 gives suppliers opportunity to focus on R+D MANY of the top global machinery and material suppliers will be exhibiting new and surprising developments at the K show in October. That’s in spite of the generally negative sentiment in the industry over the past few years: in fact, the reduced sales activity post-2009 appears to have given several of the suppliers opportunity to focus further on R+D. The period since the 2009 global financial recession has had many manufacturers on the back foot, but as SA Plastics publisher, Martin Wells found on a K preview tour to Germany in June, quite a number of the European and international suppliers have spent the time busily in the research and development area. Groups such as Reifenhäuser, Arburg and Engel are poised to introduce some fundamentally new technologies at K2013, which runs in Düsseldorf from 16-23 October. That’s timeous as far as the organisers, Messe Düsseldorf are concerned. As has happened so many times before, the German plastics and rubber show has again managed to increase exhibitor numbers and total floor space – in the process retaining its status as the top show for the industry globally. About 3138 exhibitors will be at the K, up from 3097 in 2010, total floor space utilized increases from 164,117m² to 171,033m². As expected, there is a slight decline in exhibitor numbers from the West, including Germany (there will be 1018 German exhibitors at this year’s event as opposed to 1074 in 2010) but that’s been offset by an increased number of exhibitors from China and India, who are beginning to show real leadership in the equipment and material supply sectors. Technical moulding: Intelligent solutions with perspective – More and more high quality optical components for cars and lighting in buildings are being produced using synthetic materials. Two factors are driving this trend. Firstly, glass is being replaced by lighter polymers that can be processed more cost effectively; and secondly, plastics offer greater scope in terms of product design. The challenge is to strike the right balance between superior optical quality and high cost effectiveness – and at the K event, Engel will demonstrate how to achieve this balancing act by means of overmoulding. (PICTURE: ENGEL)

China has achieved the biggest percentage increase: 342 Chinese exhibitors are to participate this year, compared to 247 in 2010. And India is also achieving an impressive increase, with 143 companies exhibiting (up from 122). The other outstanding performer is Turkey, which will have 96 exhibitors – a major increase from the 70 present in 2010. About the only other Western country to achieve improved stats is Switzerland (up to 100 exhibitors from the 86 at the previous show). The performance of other national industries that may be of interest to people in the industry in Africa include Argentina (3 exhibitors, up from 2 last time); Australia (5, up from 4); Egypt (4, up from 3); Brazil (10, down from 14); Iran (4, down from 5); Malaysia (11, down from 16); Saudi Arabia (6, up from 3), South Korea (42, up from 28), Thailand (9, 9); United Arab Emirates (5, down from 11) and Vietnam (2,2). www.k-online.de

European plastics industry is cautiously optimistic Faces up to challenges on many fronts IN THE RUN-UP to K2013, the European plastics industry finds itself fighting battles on several fronts, many of them conditioned by the uncertain state of the overall economy in the region. Austerity measures in many countries have affected investments in building and construction projects; consumers are not buying as many new cars as they used to; yet smaller, more affordable products that continue to sell well, such as smartphones and tablets, are made elsewhere. The downturn in the European automobile industry has im AUGUST / SEPTEMBER 2013


SA exhibitors Sun Ace

Reinforced fibre and nonwoven material combined – Reifenhäuser Reicofil, a provider of spinbonding lines, has developed a process to manufacture fibre-reinforced plastics. The lightweight material is the first to combine reinforced fibre and nonwovens. In tests at the RWTH Aachen, the new semi-finished product was directly compared to the current market standards in automotive engineering and aircraft construction, and compared very favourably. Organic sheets are lightweight fibre composite parts with a thermoplastic matrix. The plate-shaped fibre composite material made of fibre tissue or fibre layers is embedded in a thermoplastic matrix, which is typically a plastic film. The individual layers of film and reinforced fibre are consolidated with heat and pressure and then cooled down to organic sheets. The plates can be reformed to component parts by reheating them

The special ‘Plastics move the world’ show at this year’s K2013 will focus on five areas which represent the vast applications and properties of polymer materials. ‘Plastics move – people’ for example, focuses on personal mobility with the help of cars, trains, public transport and aircraft

THE Sun Ace group will exhibit at the K show alongside its European partner Reagens SpA for the fifth consecutive time. The heavy metal-free movement is well advanced in the South African market and the Sun Ace-Reagens global partnership continues to innovate in this field. Technical sales manager Alistair Calder invites all customers to visit the stand, Hall 6 Stand D55. Excellent collaboration with international colleagues and, of course, great Italian hospitality will be available! www.sunace.co.za

Mactec KURT Lammel of Mactec of Johannesburg will be exhibiting at the K on a joint-stand with his company’s European partner, Mactec Maschinenbau. Mactec produces a range of bagmaking machines. Mactec has improved and fine-tuned its bagmakers and further added to the product range. Hall 3 Stand E96. www.mactec-maschinenbau.de

BASF BASF South Africa will be represented at the group’s stand. This will be one of the biggest stands in the materials halls, with BASF set to introduce several new materials and technologies. Hall 5 Stand C21. www.basf.com

Plastichem THE Plastichem team will be present on the stand of their European partner, Grolman & Co. Hall 8A Stand H29. www.plastichem.co.za

Relloy DEAN Toi and Christian Grafl of Relloy will be present on the Erema stand in Hall 9 Stand C 05. Relloy also represents Reiloy, the top German manufacturer of screws and barrels, which will be present as part of the Reifenhäuser stand. www.relloy.co.za

portant consequences in the supply chain. Automotive production in Western Europe could fall by as much as 8.5% in 2013. This is likely to affect business and investments at plastics component suppliers. An exception to this trend does appear to be the UK. “The UK automotive industry has benefited from investments in new generations of vehicles, we are experiencing a renaissance of industrial activity for automotive industry suppliers,” said Philip Law, Public & Industrial Affairs Director at the British Plastics Federation. “A significant volume of business is returning to the UK.” Despite automotive woes, the plastics processing sector, in Germany at least, continues to grow at least as quickly as GDP. Turnover was at a record high in 2012, although growth slowed to GDP levels. Sales of plastic packaging and films in Germany fell by 0.4%, in 2012 as packaging manufacturers continued to face increases in raw material prices and higher energy prices. Bioplastics still occupy a niche of the plastics market in Europe

that is growing, helped by developments in technology and by changes in legislation. Carrier bags in non-biodegradable plastics are being phased out in Italy by law, and bags in biodegradable materials are taking their place. Other European countries could follow suit. Across Europe, major machine makers continue to invest. For example, in Austria, Engel will spend €12 million at its Schwertberg headquarters, where it will extend its assembly and shipping area for injection moulding machines; Sumitomo Heavy Industries has put €20 million aside for the modernisation of production at its Sumitomo (SHI) Demag operations in Schwaig and Wiehe, Germany. Germany remains the European plastics processing machinery powerhouse. Sales from German plastics and rubber machinery manufacturers rose 6% in 2012, reaching a new record. Sales peaked at €6.5bn, beating the record of €6bn set in 2011. The previous record had been in pre-recession 2008. www.k-online.de AUGUST / SEPTEMBER 2013 


ULTRA FLAT’ system makes blown film

K2013: EXTRUSION

fit for true high-speed conversion REIFENHÄUSER Kiefel Extrusion has developed and patented a new technology that allows flattening of blown film in a more effective and energy efficient manner than all other systems available in the market. The technology is the company’s response to the theoretical performance potential of modern high-speed conversion systems whose maximum production speeds can now be exploited in practice thanks to the improved film flatness quality. The established technology used so far in the industry for flattening of blown film was fundamentally rethought by Reifenhäuser Kiefel Extrusion in order to obtain film with enhanced quality in a more efficient and cost effective manner. While in the past, flattening units were arranged just in front of the winder, ‘Evolution Ultra Flat’ is installed exactly at the point where optimum processing conditions are available for flattening: upstream, between the haul-off nip roll assembly and turner bar system. Flattening via stretching is significantly improved since the melt is still not fully crystallized at this point. The amount of stretch can be adjusted by the heating and cooling rolls which are designed for independent speed and temperature control. Thus, producers are able to adapt the process to the individual requirements of the different end products

and counteract sagging of the web. The result is faster and easier conversion at high speed and less waste. Due to the fact that the film at this point is still at a temperature of over 50°C, it is possible to use the inherent heat for stretching. This means that it is not necessary to heat the film up again, in the subsequent process, to approximately 40°C. In addition, the energy consuming

cooling of the film is avoided due to the longer distance between flattening and winding systems. • FERROSTAAL IS THE AGENT FOR REIFENHÄUSER-KIEFEL IN SOUTH AFRICA www.ferrostaal.com www.reifenhauser-kiefel.com

Flattening of the film via stretching is significantly improved since the melt is still not fully crystallized at the point where the ‘Evolution Ultra Flat’ haul off unit is now positioned

New line concepts for production of special films AMONGST several new line concepts at this year’s K show, Brückner Maschinenbau will be introducing new lines for the manufacture of high-quality BOPP films which can achieve working speeds significantly higher than the previous 525m/min. Other innovations on exhibit by Brückner include:

An improved layout for BOPP high-speed lines with a new chain track system for groundbreaking working speeds. A new high-speed and energy efficient BOPP extrusion system. A number of new developments for BOPET packaging film lines which will improve still further the film quality and the operating stability and efficiency.

Simultaneous stretching: the new LISIM generation from Brückner Maschinenbau, specially designed for top-quality thinner films of between 0.5 and 75μm, including polyamide packaging films or ultra-thin BOPP and BOPET capacitor films

Simultaneous stretching: the new LISIM generation, specially designed for topquality thinner films of between 0.5 and 75μm, including polyamide packaging films or ultra-thin BOPP and BOPET capacitor films. Lines for battery separator films: latest R&D results such as reduction in film thickness, in order to increase the power density of batteries. Further new developments in specialty film lines for high-quality simultaneously stretched polyamide films, extra-thin capacitor films under, technical and optical films, PP multi-layer films (5, 7, 9 layers).

www.brueckner.com

 AUGUST / SEPTEMBER 2013


1st 14-layer air bubble film line IN the last century Colines was the pioneer in air bubble film technology, developing the 10-layer co-extrusion. Now Colines have introduced another innovation: the innovative 14-layer air bubble film line producing top quality film thanks to a special structure. Colines is a worldwide leading manufacturer of extrusion lines to produce mono and coex air bubble film with PE, PP and PA. Colines has sold more than 200 lines all over the world and has 40 years of experience in this field (the first in-line production dates back to 1973).

THE NO. 1 FOR WORLD PREMIERES: K 2013 Get ready for your most important global business and contact platform. On a net exhibition space of more than 168,000 sqm, some 3,000 exhibitors from over 50 countries will be presenting innovative solutions and visionary concepts in the areas of machinery and equipment, raw materials and auxiliaries, semi-finished products, technical parts and reinforced plastics. Plan your visit now. Welcome to your K 2013.

• Represented in South Africa by Mactec Machinery tel: 011 884 1223

www.colines.it

International Trade Fair No. 1 for Plastics and Rubber Worldwide

Mercedes, BMW production with Kiefel machines KIEFEL has notched up two major successes in the automotive sector in recent months: the production operations of the renowned prestige German car manufacturers BMW and Mercedes both rely on machines supplied by the Bavaria-based company. In the case of BMW, Kiefel has developed no fewer than seven laminating machines which are used to make the door interior trim of the new 3 Series produced in Germany, South Africa and China. Each of these machines takes just 80 seconds to produce a complete set of door interior trim components for a car. After BMW, Mercedes is the second large car producer in the last few months to have started using Kiefel machines to produce interior trim components. Mercedes ordered a total of six laminating units, which it uses to produce the door interior trims of the new C-Class. All of these machines have been equipped with an in-mouldgraining tool developed by Kiefel. • REPRESENTED IN SOUTH AFRICA BY FERROSTAAL EQUIPMENT SOLUTIONS TEL: 011 608 4445 www.kiefel.de

k-online.de

Southern African – German Chamber of Commerce and Industry 47 Oxford Road _ Forest Town, Johannesburg P.O. Box 87078 _ Houghton 2041 Tel. +27 (11)486 27 75 _ Fax +27 (11)86 639 56 77 tradefairs@germanchamber.co.za

www.germanchamber.co.za

Piggyback solution saves space THE special appeal of the twinEX/conEX piggyback solution form battenfeld-cincinnati for coextrusion presented at the K lies in its space-saving and user-friendly design. The conEX 63 P conical extruder mounted in piggyback configuration on a twinEX 78-34P also meets all requirements of high energy efficiency, since both extruder models are equipped with proven energy-saving features as standard. More and more recycled materials are incorporated in the production of window main profiles and in some cases, these materials make up more than 40% of the total weight. battenfeld-cincinnati has designed the twinEX/conEX piggyback extruder combination precisely for such applications with a high proportion of regrind. The two counterrotating twin-screw extruders combined achieve an output of about 500kg/h, with the parallel twinEX 78 being able to plasticize up to 290kg/h, and the conical conEX 63 handling up to 220kg/h. • Represented in South Africa by Maritime Marketing tel: 011 466 1717

www.battenfeld-cincinnati.com

AUGUST / SEPTEMBER 2013 


K2013: INJECTION MOULDING

BOY shows small, energy efficient machines

Single-stage PET processing goes all-electric PET processors finally have the possibility to produce any size PET bottle up to 20 litres and any size PET jar up to 145 mm neck diameter on an all-electric single-stage machine, with all the advantages of all-electric production as well as all the benefits of single-stage processing. Cypet Technologies Ltd has made this possible by introducing two all-electric machine models, based on its proprietary single-stage PET processing technology. The innovative Cypet single-stage process was originally implemented using energy-saving servo-hydraulic injection technology, with three machine models covering all sizes of PET bottles and jars production. Now Cypet’s new all-electric machines will complement the three servo-hydraulic machine models that the company has on offer. Servo-hydraulic technology uses a servo motor to drive the hydraulic pump, so that by controlling the motor speed, the pump delivers accurately the oil pressure and flow that the machine requires, without any waste of energy. In addition to saving an estimated 30% of electricity usage, this technology has a faster response time and therefore a higher movement repeatability and process consistency, compared with conventional hydraulic technologies Compared to servo-hydraulic technology, the primary advantage of all-electric PET processing is cleanliness, eliminating the risk of contamination from hydraulic oil leaks. Additional important benefits include further savings in electricity consumption, the precision and repeatability of the process, the availability of parallel movements for saving cycle time and the lower maintenance requirements. www.cypet.eu  AUGUST / SEPTEMBER 2013

BOY, the specialist for injection moulding machines with clamping forces below 1.000 kN,will set another milestone during the K2013 when it introduces its BOY 55 E equipped with a servo drive and with an efficiency classification of 8+. Alfred Schiffer, managing partner of BOY says: “We will present ourselves in Düsseldorf as the manufacturer of the most energy-efficient injection moulding machines in our market segment. We see a trend towards ‘smaller’ machines. which allow the user to respond with flexibility to ever-changing demands and achieve more secure higher quality requirements.” The new BOY 25 E is the successor to the BOY 22 E. Delicacy dishes will be moulded during the event. The new BOY 25 E is a complete new development, based on proven machine components from the previous models. Also new at the K will be the BOY 25 E VH. The insert moulding machine will be equipped with a horizontal injection unit and enables parting line injection. During the K the insert moulding of hexagonal pencils

Efficiency classification of the BOY 55 E

with a T-handle in a two-cavity mould will be demonstrated on this newcomer. • REPRESENTED IN SA BY PMS PLASTICS www.dr-boy.de www.pmsplastics.co.za

All-electric, highly precise, tie-bar-less IN TIME for K2013, Engel has expanded its range of all-electric e-motion injection moulding machines to include a tie-bar-less 30-ton version. The new Engel e-motion 30 TL combines maximum precision and energy efficiency with low machine weight and a compact design, setting a new global standard in the manufacture of precision optical parts and electronic components. The most striking innovation is that the Engel e-motion 30 TL has a new kind of ‘intelligent’ frame concept in place of the double machine frame. This guarantees very high platen parallelism together with an even distribution of clamping force across the entire mould fixing platen. The sealed three-point toggle lever with maintenancefree crank mechanism works with a servomotor to facilitate very short dry cycles of well under one second. The servo-electric ejector and mould height adjustment are integrated into the moving mould fixing platen. As with all Engel e-motion machines, the main movements are servo-electric; this makes it possible to synchronise parallel movements. The Engel e-motion 30 TL is equipped with the established in-line injection unit 50, which now delivers an injection speed of 800mm/s. Three barrel diameters are availHighly compact at just three metres in length: the new tie-bar-less Engel e-motion 30 TL injection moulding machine.

able as standard: D15, D18 and D20. With a length of just 3m, the new machine offers a highly compact design that saves floor spacel. Moreover, thanks to tiebar-less technology, it is possible in many applications to use a smaller machine than mould size would normally dictate. With no tie-bars in the way, mould fixing platens can be used to the hilt. Tie-bar-less technology also makes mould changes easier and speeds up automation as direct parts handling is possible from the side. The Engel e-motion 30 TL is ideal for manufacturing high quality optical components and electronic parts such as connectors for mobile devices. • REPRESENTED IN SOUTH AFRICA BY MARITIME MARKETING www.marimark.co.za www.engelglobal.com


Specialists in Sales, Service & Repairs of a Diverse Range of Injection & Blow Moulding Machines & Auxiliaries

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4 Newton Road, Hughes , Ext. 15 Boksburg P O Box 6250, Dunswart 1508 Tel: +27 11 823 5840/41• 823 4952/54 • Fax: +27 11 823 4969 Email: mail@pmsplastics.co.za • www.pmsplastics.co.za


K2013: INJECTION MOULDING

Ferromatik focus on packaging technologies MACHINES from Ferromatik Milacron at Mold-Masters and DME booths, both of which are part of the Milacron group, will underscore the company’s international theme at the K this year. The modular F-Series is focused on packaging technologies, including InMould-Labelling, barrier injection and cube technology. Ranging in size from 500 to 6,500 kN, the series can be configured as an all-electric, hydraulic, or hybrid machine. At K 2013 visitors will see an all-electric F 200 with a clamping force of 2,000 kN equipped with a size 50 Advanced Performance (APe) electric injection unit. Using a 4-cavity mould and an IML system by H. Müller from Switzerland, this machine will demonstrate production of thin-walled rectangular lids with labelling. Every 3.1 s, four lids with labels weighing 8.2 g are produced. An F 350 hybrid with a clamping force of 3,500 kN is especially notable for its speed. This machine uses a size 70 Advanced Performance hydraulic injection unit. Driving a 64-cavity mould by Corvaglia (Switzerland), the machine will produce 33 mm beverage closures with a part weight of 2.6 g every 4.5 s. The third machine in the F-Series at the Ferromatik Milacron both is an all-electric 2,700 kN cube moulding machine, the F 270 CUBE. The machine has generous tie-bar spacing of 750 x 750 mm. It features an electric

rotating mechanism within the machine and an 8+8 cavity cube mould with four sides. This machine configuration makes use of an electric General Performance (GPe) size 50 main injection unit as well as an electric GPe 45 traversing injection unit, mounted over the clamping unit on the moving platen. The fourth machine in the modular F-Series will be on display at the Mold-Masters booth. Here a 1,600 kN F 160 can be seen, incorporating a hydraulic Advanced Performance (APh) size 45 injection unit in combination with a vertically mounted E-Multi injection unit built by Mold-Masters. Using a 16-cavity mould, this machine will demonstrate production of closures with two components using barrier injection. The

Lid with labelling produced on a 2000 kN all-electric F200 injection machine

4.3 g closures are produced with a cycle time of 4.2 s. K2013 will see the introduction of a new small machine with a clamping force of 300 kN bringing the total number of machines in this series to eleven, ranging from 300 to 5,500 kN. The Elektron 30 will feature an international size 55 injection unit and will produce applicators for 1 ml medical ampules on a four-cavity mould with a cycle time of 9.1 s, and a part weight of 1.6 g. • FERROMATIK IS REPRESENTED BY SES IN SOUTH AFRICA WWW.SESCC.CO.ZA

www.ferromatik.com

Freedom has to be experienced Faces up to challenges on many fronts UNDER the slogan of “Freedom has to be experienced”, Arburg will focus on production efficiency and, with more than ten exhibits, will demonstrate how plastic parts can be produced efficiently in the future. Among the injection moulding machines, the electric Allrounder 820 A, which completes the high-end electric Alldrive machine series, will celebrate its world premiere in Düsseldorf. Both the 4,000 kN toggle-type clamping unit and the size 2100 electric injection unit have been newly developed for this machine. The same applies to the high-performance hybrid Hidrive range,  AUGUST / SEPTEMBER 2013

for which this new toggle size will also be available in future. A further highlight is the fully-electric cube-mould application for the production of juice container closures, which will be presented jointly with Arburg partner Foboha. On the electric two-component Allrounder 720 A with a clamping force of 3,200 kN, the large size 800 injection unit is arranged horizontally and the small size 400 injection unit is arranged horizontally and on the moving mounting platen of the machine. • ARBURG IS REPRESENTED IN SOUTH AFRICA BY HESTICO WWW.HESTICO.CO.ZA

The second injection unit of the electric two-component Allrounder 720 A is arranged horizontally and on the moving mounting platen of the machine. With the cube-mould application, both rotation of the cube mould and the linear mould movement are driven electrically

www.arburg.com


- passionate about the plastic industry. Supplier of:

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K2013: ANCILLARIES

Motan’s Spectrocolor G dosing & mixing station for production of yarn fibres MOTAN will present equipment, systems and services based on its comprehensive process understanding at this year’s K show. The new range of small compressed air dryers with hopper volumes of 0.75 / 1.5 / 3 and 5 litres are one of the highlights among the exhibits. With the new gravimetric (loss-in-weight principle) collecting bin, demanding floodfed processes (using single-screw and counter-rotating twin-screw extruders) can now be connected to the Spectrocolor G dosing and mixing station. The main application is in production of yarn fibres, as here the material level above the extruder has to be kept as low as possible in order to prevent material de-mixing in the collection bin. The new HT high temperature version has been designed for material input temperatures of a maximum of 180°C. High temperature applications such as production of high temperature fibres in PA and PET/PBT are also possible. Highest mix consistency is achieved with the motan gravity mixing principle. Reliable material filling of the weigh bin is guaranteed by a material loader with a pneumatic discharge flap or via a double slide valve with supply hoppers.

This completely covers the entire extrusion processing spectrum (production of pipes, hoses, profiles, as well as blown and cast film, sheets, fibres and tapes), but also compounding. Up to six components, each with a throughput range of 0.2 to 1.200 kg/h per dosing axis can be synchronously and gravimetrically dosed and mixed with the Spectrocolor G dosing and mixing station. • PLASQUIP IS THE AGENT FOR MOTAN-COLORTRONIC

www.motan.com www.plasquip.co.za

With Motan’s new gravimetric (loss-in-weight principle) collecting bin, demanding flood-fed processes (using single-screw and counterrotating twin-screw extruders) can now be connected to the Spectrocolor G dosing and mixing station

Automatik: Profitable drying of sensitive compounds THE DURO belt dryer is specially designed for drying abrasive and sensitive compounds. It is used primarily in underwater pelletizing. Using the Duro belt dryer significantly reduces operating costs because the innovative design of its pellet-contacting components means very little wear occurs in operation. Duro gently dries glass fibre reinforced products or high-fill mineral compounds to residual pellet moisture levels of less than 0.1%. Gentle treatment of the pellets minimizes dust and greatly enhances product quality. Duro is particularly suitable to operations involving frequent product changes because it is very quick and easy to clean. The wide range of available options means it can be easily retrofitted in existing pelletizing systems so as always to ensure optimally tailored drying variants. www.maag.com  AUGUST / SEPTEMBER 2013


We lead... others follow National Sales Number: +27 11 902 8923 FAX: +27 11 902 8980 email: jhb@plasquip.co.za www.plasquip.co.za Please call for your local costal representative details and office number


K2013: ANCILLARIES & MATERIALS

Moretto control & management for conveying systems MORETTO S.p.A. (Massanzago, Italy), will showcase its One Wire 6 (OW6) self-adaptive control and management for conveying systems at this yearâ&#x20AC;&#x2122;s K show. The control system for centralized conveying systems is now completely automatic. A machine that collects the material to be processed at 20m distance can be connected to the stored material at 100m distance - simply connecting the machine to the desired pipe, and no data or parameters need to be modiďŹ ed. One Wire 6 will also be able to recognize the new conditions and will self-adapt. One Wire 6 has a 10â&#x20AC;? touch screen interface for production control and is also equipped with a Master 600 palm top to create customized proďŹ les. The OW6 server is able to manage up to 80 clients among receivers, suction units and automatic manifolds. â&#x20AC;˘ REPRESENTED BY GF PLASTIC MACHINERY SERVICES TEL: 011 975 4035

 AUGUST / SEPTEMBER 2013

 

  

Hydrolysis-resistant PBT for automotive electrics The hydrolysis-resistant PBT UltradurÂŽ HR not only stands out in a positive way in customary static tests for damp-hot environments, but also passes the demanding climatic cycling tests of USCAR standard class 5. It could be shown that Ultradur HR is superior to competitor products. BASF now offers Ultradur HR with integrated ďŹ&#x201A;ame retardance and laser transparency respectively. The material is thus suitable also for applications in electric vehicles. Examples are control housings (photo) or charging plugs, but also parts that have to be laser-welded from several components. (PHOTO: BASF, 2013)

www.ultradur.de

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Inorganic pigments for exacting requirements LANXESS will be showcasing a wide range of inorganic pigments for colouring plastics at K2013. The Colortherm iron oxide and chrome oxide pigments speciďŹ cally developed for the plastics industry come in yellow, red, brown, black and green. Numerous shades of the individual colours are available. The range includes both universal products and specialty products for special requirements. Each product has its own deďŹ ning characteristics, such as thermal stability, tinting strength, lightfastness, weather stability and brilliance. Applications for Colortherm include packaging materials, tubes and connecting elements, cockpits and synthetic leather in the automotive industry, plastics in the electronics and electrical industry, synthetic

Applications for Lanxessâ&#x20AC;&#x2122; Colortherm include wood-plastic composites

running surfaces on athletic tracks, and WPCs (wood-plastic composites). The pigments are easy to process and their special micronization paves the way for high productivity, because the very ďŹ ne powder is dissolved quickly in the plastic. Thanks to the pigmentsâ&#x20AC;&#x2122; excellent thermal stability, they can be heated to temperatures of over 300°C, depending on the grade, and suffer no adverse effects during the extrusion of the coloured polypropylene ďŹ bres.

An important application for Colortherm Yellow in conjunction with organic phthalocyanine pigments is colouring artiďŹ cial turf, which is becoming increasingly popular and signiďŹ cantly reduces maintenance costs for stadiums with grass ďŹ elds. www.lanxess.com

AUGUST / SEPTEMBER 2013 

  

 

 "!# ! !!  !

Impressive ideas for storing, processing & conveying ZEPPELIN Systems has long been among the top suppliers in the ďŹ eld of silo construction and pneumatic conveying systems for the plastics industry. Zeppelin builds turn-key plants for producers and processors of plastics. Henschel Mixing Technology, a business unit of Zeppelin Systems, has developed a new series of cooling mixers with outstanding cooling efďŹ ciency. The Mixer HCE (Horizontal Cooler EFF) is available in sizes ranging from 1,700 to 6,000 litres. The HCE series has already been tried and tested in PVC manufacturing. Until now, producing PVC dryblends required blending and heating the PVC with ďŹ llers and additives in a heating mixer to ďŹ nally cool it in a cooling mixer. Due to the cooling capacity required and the time available, the cooling mixer had to be 2.5 times larger than the heating mixer. Now, much smaller cooling mixers can be used.

www.zeppelin.com

    

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K2013: MATERIALS

Closing the gap with heat resistance For automotive window sealing applications, Teknor Apex can supply either TPV or styrenic TPE compounds, both under the Sarlink brand

Teknor Apex restructures TPE brands TEKNOR Apex Company will introduce a restructuring of its thermoplastic elastomer (TPE) brands that will enable it to serve as a single source of multiple compounds for European plastics processors in industries as diverse as automotive, medical, consumer products, and wire and cable. All TPEs applicable to a particular enduse sector will now be grouped under a single brand, regardless of how widely the compounds differ in terms of polymer chemistry. For the first time Teknor Apex can produce compounds spanning the entire range of these chemistries at its plants in Belgium and the UK. Included are many Teknor Apex TPEs developed in the USA and previously unavailable in Europe. For example, the Sarlink® brand once consisted exclusively of thermoplastic vulcanizate (TPV) compounds but has been expanded to include styrenic and olefinic blends – until now produced by Teknor Apex only in the USA. “Today Sarlink represents a complete solution for the transportation market,” said Ger Vroomen, senior automotive market manager. “For designers of automotive sealing systems, in particular, Teknor Apex can provide a TPV or styrenic compound as an alternative to EPDM rubber, depending on customer requirements, and it is the only supplier in a position to do so.” Similarly, the company’s Elexar®, Medalist®, and Monprene® brands now include all TPE types designed for use in electrical/electronic, medical, and consumer-product applications, respectively. • ADVANCED POLYMERS IS THE SA AGENT WWW.ADVANCEDPOLYMERS.CO.ZA

www.teknorapex.com  AUGUST / SEPTEMBER 2013

Ultramid® Endure now also available as blow moulding grade BASF developed the heat-resistant material Ultramid® Endure in 2010 - to date, the most heat-resistant, polyamide-based injection-moulding material available in the market. Now BASF is introducing a blowmoulding grade of Ultramid Endure called Ultramid Endure D5G3 BM and it closes the gap of efficiently manufacturing pipes by blow moulding. In 2012, one of the first serial applications for the injection-moulding grade Ultramid Endure D3G7 was the substitution of a heat shield in the charge-air duct which had previously been metallic. With its temperature resistance of 220°C in continuous use and peak temperature loads of 240°C, the material can also be used for a lot of other components behind the turbocharging, that is, on the resonator, on sensors and actuators, on the intake side of the intercooler and in the charge-air manifold. The pipes between the turbocharger and intercooler which are subjected to the same high temperatures can best be manufactured by blow moulding with the new Ultramid Endure grade. The new Ultramid Endure D5G3 BM with a glass fibre content of 15% shows a high heat aging resistance, is easy to process, and has outstanding acoustic properties. As with the injection-moulding grade, the temperature resistance is 220°C during continuous use and the possible peak tem-

BASF’s most heat-resistant, polyamide-based injection-moulding material in the market is now also available as blow-moulding grade. The new grade is called Ultramid® Endure D5G3 BM and has the same stabilization technology as the injection-moulding type Ultramid Endure. It also shows the same temperature resistance of 220°C in continuous use and peak temperature loads of 240°C (PHOTO: BASF)

perature is 240°C. The relatively low melt temperature during processing with blow moulding generally results in favourable system costs. Ultramid Endure performs significantly better than for example PPS (polyphenylene sulfide). www.ultramid.de

The first soft Ultramid S Balance grades for extrusion Since BASF introduced the first glass fibrereinforced PA610 injection moulding grades of Ultramid® S Balance at the K 2010 Plastics Trade Show, the material has found use in numerous applications because of its special characteristics. Because of the current demand in the market and on the basis of its years of experience in extrusion, BASF decided to expand its PA610 line of products. At K2013 it will introduce two flexible grades of Ultramid S Balance that are suitable for extrusion of pipe and tubing intended for use specifically in the automotive and machinery sectors as well as for oil and gas lines. They are Ultramid S4Z5 Balance and Ultramid S4Z4 XS Balance. The two long-chain polyamide compounds are characterized by especially low moisture uptake, good resistance to chemicals and stress cracking as well as low-temperature impact strength. They will be available in sample quantities as of November 2013

www.basf.com


uppe marketing A08303

Fresh portfolio. Colour your world!

BASF's Official Distributor: Lake International Technologies Sherisha Ramruthan Sherisha.Ramruthan@lake.co.za Tel: +27 11 409 5000 (switchboard) Fax: +27 11 388 6423 (direct ) CALL CENTRE: 0860 99 00 11

BASF South Africa (Pty) Ltd (Plastic Additives) Charis Lewis Tel: +27 11 203 2596 Cell: +27 71 670 2407 Fax: +27 11 203 2602 E-mail: charis.lewis@basf.com


K2013: RECYCLING

New core technology from Erema A milestone in plastic recycling system engineering EREMA, a global industry leader in plastic recycling systems will once again cause a technological sensation in the company’s 30th anniversary year when it presents a new core technology at K 2013. Since it was founded in 1983, Erema has specialized in the development of plastic recycling. The heart of the Erema systems is formed by the large patented cutter/ compactor and extruder combination which can be used for a wide variety of recycling jobs according to the configuration in both in-house production waste recycling and severely contaminated post-consumer waste applications. Erema managed the major breakthrough with the first generation of systems launched in 1983, the year it was founded. It combined for the first time ever a cutter/ compactor with a – back then still radial – extruder and thus made it first possible to cut, compact and extrude waste plastic in a single, continuous process. The machines were straightforward to operate, had low space requirements and consumed on average 30% less energy compared to the industry standard at that time. Erema continued to develop this technology and with the launch of the second plant generation in 1993 once again brought about advancement in the industry on a large scale. Thanks to the extruder now being located tangentially to the cutter/

compactor, Erema was able to enhance the quality of the end products enormously while increasing output and performance considerably. A newly defined and optimized scaling of the cutter/compactor in relation to the screw diameter of the extruder connected (patented) made feeding even easier with very large individual portions. Erema’s patented add-on technologies for specific applications such as Double Disc and Air Flush Module, for example, not only ensure high material quality but also broaden the processing range of the systems. Thanks to the continuous and new development of plastic recycling technologies and plant systems in subsequent

years, these were followed by innovation highlights such as the products Vacurema® PET recycling systems for direct food contact, TVEplus® for heavily printed/ contaminated plastic waste, Coax® for large-volume material portions (such as fibre bales, ropes, automotive parts, etc.) and Corema®, a combination of proven recycling and compounding technology for specific recyclates. • REPRESENTED IN SOUTH AFRICA BY RELLOY www.erema.at www.relloy.co.za

Herbold Meckesheim washers & dryers FOR professional recyclers and for the recycling of mixed plastics, Herbold Meckesheim GmbH is a hallmark name. The whole range of machines from shredders to granulators, washing and separation lines to plastcompactors make up the product line of the

machine and plant manufacturer. An impressive line-up of new developments will be displayed at this year’s K show, illustrating the new trend of always bigger with an always higher throughput and a better quality with less energy consumption. The new mechanical dryer (type HVT) with a vertical rotor arrangement is a particularly space-saving and extremely service-friendly version. Energy consumption is with certain materials, such as PET flakes, considerably lower than with former models. A new model of friction washers will be launched, the FA 60/300 type covering the performance range of 2 – 3 t/h for films and 4 – 6 t/h for rigid plastics. • REPRESENTED IN SOUTH AFRICA BY VALOZONE 132 - TEL: 011 742 1812

Mechanical Dryer Type HVT

Herbold Friction Washer Type FA 60/300

 AUGUST / SEPTEMBER 2013

www.herbold.com


K2013: ADDITIVES

Cutting edge solutions from Clariant CLARIANT continues to expand its toolbox of cutting-edge, efficient phosphinate flame retardants with new tailor made formulations. These include Exolit OP 1400 for polyamides with special requirements and Exolit OP 1260 for polyesters. Clariant will focus on the added-value for plastics manufacturers offered by montan wax specialties, such as Licomont NaV 101 and CaV 102, which significantly reduce cycle times and provide excellent release and flow properties for injection moulded polyamides and polyesters. The innovative Licocene grades are also highlighted for high performance masterbatches. The new AddWorks Polymer Additives Solutions, such as Addworks ATR for automotive, or Addworks ELC for E&E, will further contribute to expanding the features of engineering plastics in terms of polymer

protection, process stabilization, and productivity improvement or energy savings. Clariant will also bring liquid masterbatches to life at K 2013. Clariant’s Liquid Masterbatches carrier technologies are designed for a variety of different polymer and production processes and, together with Liquid Masterbatches dosing - and handling – systems, provide the flexible way to advance plastics. Clariant’s Liquid Masterbatches EBM monolayer systems offer a significant reduction in colour change time, and a troublefree and continuous manufacturing process. www.clariant.com High-performance montan wax specialties for shorter cycle times and increased output: Licomont® CaV102 and NaV101. (PHOTO: CLARIANT)

Custom-made for coating plastics PROELL KG’s core business lies in the development of custom-made chemical products for coating and decorating plastics and other materials, as well as innovative ink systems for IMD/FIM technology, and screen and pad printing inks. At K2013 this prowess will be showcased by producing trolley coins with a Dr. Boy XS injection moulding machine and decorated by film insert moulding (IMD technology). Norilux® DC is a formable, abrasion resistant Dual-Cure screen printing lacquer which can be used as protection lacquer or hard coat on PC and PMMA films. It is ideally suited for first surface coating/protection of products manufactured in IMD/FIM technology. The matt version of Norilux DC can be printed on uncured transparent hard coat films such as Makrofol® HF 278 or 312 to create matt and high gloss effects

in one item. Films decorated with Norilux DC can be 3D formed after box oven drying e.g. by high pressure forming or thermo forming. The cured lacquer layer shows excellent resistances to abrasion, chemicals and cleaning agents and passes various creme tests of the automobile industry. Proell offers a wide range of IMD/ FIM screen printing inks and adhesion promoters for film insert moulding. The latest development is Noriphan XWR, a halogen-free ink system for IMD/FIM technology. Noriphan XWR shows extremely high wash-out resistance and outstanding cohesion in compound. The mild two-component screen ink can be used as decorating ink or wash-out protection layer on PC films and PET films. www.proell.de

Decorative trims – the first surface is protected with Norilux DC 5, while the second surface is printed with the IMD/FIM ink system Norophan HTR N

Addivant help improve fuel efficiency LEADING polymer additives supplier, Addivant will greet K 2013 visitors with a collection of value-adding product innovations and services Addivant focused on meeting are helping improve today’s global megafuel efficiency using trends of sustainable their additives to help shelter, potable water polymers replace access, reliable power, conventional, heavier materials and make food safety and fuel lighter cars efficiency. The company’s powder-free additive solutions deliver superior physical properties that allow for greater manufacturing productivity, including increased production up-time, improved health and safety, reduced maintenance and higher throughput in a variety of plastic extrusion applications. The advanced performance of Addivant’s materials supports lighter weight, and more durable. Products representing these benefits include new solutions from Addivant’s platforms for phenolic antioxidants, phosphite antioxidants; amines, thioesters, NDB blends; light stabilizers, polymer modifiers; polymerization inhibitors, and rubber chemicals and intermediates.

 AUGUST / SEPTEMBER 2013

www.addivant.com


THE POLYMER SOLUTIONS COMPANY Plastamid, a member of the Chemical Services Group, has brought premier polymer solutions, extensive application development and technical service to the local and international polymer markets for over 35 years. Plastamid plays a leading role in the manufacture and supply of thermoplastic compounds to a diverse range of industries.

Automotive

Electrical

Industrial

Packaging

Consumer

Compounding Service

Experience PR E MI E R P OL YM ER SOL UTION S w ith exten siv e A PPL I C A TION DEVEL OP M EN T and expert T E C H N IC A L SER VIC ES Visit www.plastamid.co.za for further information. 021I 914 9042 Johannesburg 922031 1600701 / Durban 3445 75 278 CPT 021Cape MEHTown MNHF JHB 011/ 922 1600 I 011 DBN 9546 I031PE762 08000


Thermally conductive plastics in applications

LED

Offers combination of thermal conductivity, electrical insulating, design freedom

Key benefits In spite of a large difference in thermal conductivity (W/mK) between metal and plastics, plastics materials offer suitable performance for many thermal management applications, including: Combines thermal conductivity with electrical insulating (Coolplast = 1.45 W/ mK vs standard polyamide = 0.3 W/mK)

Potential replacement of overengineered metal heat sinks Good chemical and corrosion resistance for long term usage Weight saving Design freedom Production cost reduction Colour freedom Key benefits LED housings and lighting fixtures Automotive under the hood applications Consumer electronic devices Electric/electronic components, and Temperature sensors and heat exchangers. Case study – IdeaLED.it The use of Coolplast in LED bulb applications has been validated by the success of a commercial application by a company in Italy – IdeaLED.it. The company manufactures a wide range of LED lamps and modules, as well as strips and profiles. IdeaLED.it operates from its 5000m2 plant in Montecchio Maggiore (Vicenza) in Italy. The IdeaLED.it products are designed to achieve high performance efficiency. In particular, the company has developed a new family of thermally conductive plastic compounds that allow customers to realize patented LED lamps of a particular form and size to ensure optimal thermal management. Apart from designing and producing high efficiency optical elements for modules and lamps, the company also manufactures moulds and tooling with suitable plastics materials.

The IdeaLED.it Led strips and profiles are characterized by a large variety of types and forms, colour bins that are extremely narrow to allow absolute homogeneity in installations made, and a wide range of solutions with RGB colour change dimming

70

AUGUST / SEPTEMBER 2013

The use of Coolplast in LED bulb applications has been validated by the success of a commercial application by a company in Italy – IdeaLED.it. One family of LED lamps from IdeaLED.it (the QR111) is the ideal replacement of halogen lamps mainly used for lighting commercial spaces and exhibitions. The high efficiency of the LEDs used allow an energy saving of up to 85%

NOTES # A LED (light-emitting diode) is a semi-conductor light source. LEDs are used as indicator lamps in many devices and are increasingly used for other lighting. Appearing as practical electronic components in 1962, early LEDs emitted low-intensity red light, but modern versions are available across the visible, ultraviolet, and infrared wavelengths, with very high brightness. www.plastichem.co.za www.idealed.it Pointing towards the future – Helmut Oellermann, Plastichem MD, demonstrating locally produced LEDs using Coolplast (Proplas Africa 2013)

MATERIALS

RECENT innovations in thermally conductive plastics have opened up new opportunities for thermal management solutions to dissipate heat away from the source and keep components cool. In LED# (lightemitting diode) applications especially the LED performance and lifetime is temperature dependant and effective cooling is critical. The new materials now available are a viable alternative, offering an excellent combination of thermal conductivity, electrical insulating and design freedom. Coolplast – a polyamide-based white material with heat dissipating properties – is one such material that has displaced over-engineered and costly metal-based thermal management systems in LED bulb applications. Coolplast is the trade name used for the heat dissipating polyamide manufactured by PTS, a premier independent materials specialist in Germany, represented by Plastichem in South Africa. In the past the traditional materials used for thermal management have included aluminium, brass or copper. These metalbased heat sinks are expensive and often need post-treatment operations such as painting, drilling or tapping.


ARBURG CELEBRATES

EQUIPMENT

5yr0s

History of PIM processing began at Arburg in 1963 with first ever ceramic part produced

POWDER injection moulding (PIM) pioneer, Arburg, celebrated ‘50 years of Arburg PIM expertise’ in June. The highlight of the celebrations was an international conference attended by about 200 guests from 25 countries with 16 presentations held by eminent PIM experts from Europe, Asia and North America. The surprise of the event was the official handover of the 1,000th PIM Allrounder to Swiss company Comadur. A broad range of topics was covered at the conference, including both ceramic and metal injection moulding (CIM, MIM). The PIM industries in Europe, Asia and North America were also analysed, as were the research and development prospects for the future. Key areas in which PIM products are used were presented, including the automotive, jewellery and watch-making industries, as well as the IT and dental sectors. The presentations also covered all aspects of the value-added chain, with topics ranging from the effect of feedstock preparation on component quality and the complex production of micro PIM parts, to cost-effective component integration and production using complete turnkey systems. Appropriately for the event, the programme not only covered current topics,

but also looked back over 50 years of PIM expertise at Arburg. Helmut Heinson, Managing Director Sales, and Stephan Doehler, Director Sales Europe, who chaired the entire event, recounted a history of successful development. In 1963, the history of PIM processing began at Arburg with the first ever ceramic part produced on an Allrounder 200 S by company Feldmühle. This was a geometrically complex pigtail thread guide for the textile industry. All-round support from Arburg Over subsequent years, demand continuously grew both for the process itself and for new machines for powder injection moulding and Arburg adopted a consistent approach to the development of machines, materials and processes – often in collaboration with other experts. The company also invested in a dedicated PIM laboratory. Thanks to its comprehensive equipment, the testing of injection moulding, as well as all upstream and downstream production steps such as material preparation, debinding, sintering and part analyses can be conducted under practical conditions. 1,000th Allrounder for the PIM industry Hundreds of machines have been supplied to this sector over the past five decades, making it possible to mark

another milestone: the presentation of the 1,000th PIM Allrounder. This machine went to Swiss-based Comadur, a company that produces high-quality components for the watch industry. MD of Technology & Engineering, Herbert Kraibühler explained how Comadur had ventured into the powder injection moulding industry over 20 years ago with the support of Arburg to produce chain links for watch straps. Initial teething problems were ironed out by Arburg, laying the foundations for successful cooperation and joint development. Over the years, Arburg not only acted as a machine supplier, but also as an application technology adviser. The manufacture of black and white ceramic parts for watch casings and parts for watch straps using injection moulding involves Allrounders exclusively. The anniversary machine will bring Comadur’s fleet of machines to 21 Allrounders. Moreover, with the new Allrounder 270 A, the company will be using an electric machine for the first time. • HESTICO REPRESENTS ARBURG IN SOUTH AFRICA www.arburg.com www.hestico.co.za

Delighted to take delivery of the 1,000th PIM Allrounder: Comadur’s Director of Purchasing Patrice Jaggy (2nd from left) and Arburg’s Managing Director Technology & Engineering Herbert Kraibühler (3rd from left) with Arburg Partners Juliane Hehl, Michael Hehl, Renate Keinath (from right to left) and Eugen Hehl (left) PHOTOS: ARBURG

 AUGUST / SEPTEMBER 2013


ASB-50MB

More than one step ahead

ASB-70DPH / ASB-70DPW

Medium sized machines for small narrow-necked bottles up to wide-mouthed jars ASB-70DPH / ASB-70DPW Moderate investment costs & mould changeover times, with huge production versatility. Targeted at the medium to large bottle and jar market, while the double row preform configuration is suited for high scale production of bottles under 700ml capacity.

PM-70/65NII / PM-70/111N

Entry level machine ideal for small bottle production with exceptional capabilities ASB-50MB An all-time favourite which is continually upgraded for improved versatility and productivity. Over 1,500 units delivered in the first 9 years of production. PF6-2B / PF8-4B

Leader in PET Technology The histories of Nissei ASB and PET containers have been tied together, as will their future be. Back in the early days of injection stretch blow moulding (ISBM), Nissei ASB was a pioneer in the field and PET was just becoming established as the material of choice for beverage and foodstuff containers. Today, both Nissei ASB and PET remain firmly at the forefront of the injection stretch blow moulding industry. As for the future, no one can predict which direction the industry will take, but there is one thing you can be sure of â&#x20AC;&#x201C; wherever it goes, Nissei ASB will be right there at the front continually innovating for tomorrowâ&#x20AC;Ś

NISSEI ASB SOUTH AFRICA (PTY) LTD 97 Sovereign Drive, Route 21 Corporate Park Nelmapius Drive, Irene Ext 30 0062 P.O. Box 11785, Centurion 0046, South Africa Tel: +27 12 345 4924 Fax: +27 12 345 5667 E-mail: sales@nisseiasb.co.za

Small and medium bottle production PF6-2B / PF8-4B Capable of moulding containers up to 1.5L (PF84B) and 3L (PF6-2B). Optional neck orientation or preferential heating systems expands the capabilities for extreme oval designs. The PF8-4B is ideally suited to 500ml water or sports drinks containers, while the PF6-2B is ideal for containers in the 1.5L to 3L range. Preform production for small and medium bottle PM-70/65NII / PM-70/111N Ideally matched to the CM and HSB machines for production of hot fillable PET bottles. Also suited to any general moulding operation for a range of performs from 0.3L up to 5L, neck sizes up to 48mm (thread diameter) and from 8 to 24 cavities.

NISSEI ASB PTE. LTD. 85 Science Drive # 01-03 The Cavendish Singapore Science Park 1 Singapore 118259 Tel: (+65) 6778 4633 Fax: (+65) 6778 9440 E-mail: asbsin@signet.com.sg www.nisseiasb.co.jp


Preform, closure in one shot

EQUIPMENT

Special combination of preform neck finish, lightweighted caps SACMI and SIPA (Zoppas Industries Group), two of Italy’s most innovative companies operating in the packaging sector, have combined their skills in the search for a new solution in the combination of PET preforms and closures that provides advantages for processors and end-users alike. The collaboration, which has been given strong backing from the two companies’ managements combines SACMI’s substantial experience in caps and closures and SIPA’s with the development of preforms. The fruit of this collaboration is a new solution – S.U.P.E.R. – featuring a special combination of lightweighted caps and preform neck finish that solves several key problems associated with the operation of a cap on the neck of a PET bottle, with results previously not thought possible. S.U.P.E.R. stands for Sustainable, Unique, Productive, Easy, and Reliable - the five key benefits of this innovative solution: Sustainable, because the closure will be lighter than the average of alternatives,

reducing the processor’s consumption of raw materials and energy. Unique, because this is a proprietary solution, protected by patents. Productive, because it reduces the time and cost of equipping production lines –when switching between containers for various types of products, including water, soft drinks, and aseptically filled drinks, very little modification is required to lines for either preforms or closures (the latter produced with SACMI’s compression process, which already offers reduced tooling times and high production speed). Easy, because the solution provides the consumer with a bottle that is easy to open. The guaranteed positive LB angle – the leak angle is greater than the bridge-break angle, a feature not available on the market today with current closure solutions. Reliable, because the special tamper evidence system provides an immediate

breakage of the security strip, rendering the bottle secure, with no risk of blow-off. • SACMI IS REPRESENTED IN SOUTH AFRICA BY PETER ROELOFFZE OF COMASS OF CAPE TOWN www.sacmi.com www.comass.co.za

ENGEL launches new service era with e-calc New app for mobile devices replaces data slide rule ENGEL now offers customers even more support with a new app for mobile devices. After entering just a few parameters, e-calc automatically supplies the values required for material and componentdependent design of injection moulding machines, as well as critical setting data, ensuring that the injection moulding machine perfectly matches the application in hand. The materials data is stored in the software. Based on them, e-calc guides the user step-by-step to the results. The optimum values for the required stroke volume, the occurring filling pressure, the resulting clamping force and the screw speed and cooling time are computed. Thus far, Engel has supported its customers in machine design with a data slide rule that does not remove the need for the user to perform the required computations. Even less experienced plastics processors

can rely on the software to find the bestsuited machine within the shortest possible time. At the same time, the machine setter benefits in terms of process settings in on-going operation. They no longer need a calculator, nor do they need to enter materials data manually. The materials data for typical thermoplastics, which were previously grouped in a compact way on the slide rule, are now stored in the app. They include, for example, the melt, mould and pre-drying temperatures and times, viscosity and wall thickness factors, temperature conductivities and de-moulding temperatures, permissible peripheral screw speeds, enthalpy values and guidelines for processing loss. The Engel e-calc app is available from the provider stores in German and English for Android smartphones. Versions for iOS and Windows Phone are under development.  AUGUST / SEPTEMBER 2013

• MARITIME MARKETING REPRESENTS ENGEL IN SOUTH AFRICA www.marimark.co.za www.engelglobal.com After entering just a few parameters, e-calc automatically supplies the values required for material and component-dependent design of injection moulding machines. (PHOTO: ENGEL)


Excellence

in COLOUR

consistency

“The quality of expectations determines the quality of our action.” - Andre Godin

Our 4 divisions: ❉ Masterbatch ❉ Pigments ❉ Pastes - PUR & PVC ❉ Liquids - PO & PET

Contact us: www.performance.co.za GAUTENG:Tel: + 27 11 961 2700 | Fax: + 27 11 961 2799 | Cnr. Koornhof & Essex Roads, Meadowdale Ext. 1, 1401 CAPE TOWN:Tel: + 27 21 928 2800 | Fax: + 27 21 931 9088 | 5 Linus Road, Beaconvale Industria, Parrow 7500 DURBAN:Tel: + 27 31 701 1202 | Fax: + 27 31 701 2296 | Reed Place Maxmead Ind. Park Unit 22, Pinetown 3620 EAST LONDON:Tel: + 27 43 736 2076 | Fax: + 27 43 736 2036 7 | Reitz Avenue, Greenfields, East London

Should you wish to subscribe to our monthly newsletter, please contact Lurika: lurika.joubert@coloursystems.co.za


EQUIPMENT

LASER WELDING: Temperature of 1500°C achieved at focal point A NEW LASER deposit technology from O R Laser of Germany allows for the repair of moulds and, in fact, all precision metal components in a far more efficient manner. Precision metal parts, primarily injection and blow moulds for plastic products, often with complex metal compositions, are extremely expensive. Sooner or later, stress results in damage and cracks. Repairs by methods currently on the market (primarily argon gas arc welding) alter the metal composition around the repair and reduce the component’s quality. The O R Laser technology permits precision parts – for example, injection moulding forms – to be altered and repaired with an accuracy of a tenth of a millimetre. Heat sensitive surfaces and coatings are treated in a relatively distortion-free manner. Even the typical discoloration of the metal around the repaired area, and branding spots, does not materialize. The metal grains remain unchanged and otherwise extensive post-processing is reduced to a minimum. In most – if not all – cases, it’s difficult and even impossible to detect where the repairs have even taken place. The O R Laser technology laser process makes it possible to treat precision components of all conventional types of mould and tool steels. It can also be used on aluminum alloys, copper-beryllium and even exotic materials such as CuZn alloys (which cannot be handled by common welding procedures). A temperature of 1500°C is achieved at the weld focal point. A metallurgical bond between the base and layer materials occurs due to the fusing of the base material

Due to the fine nature of laser welding, operators need to be well trained and skilled; here we see Franz Studer of Retecon demonstrating the HTS Mobile unit in operation. The unit is suited for repairing small precision components as well as large moulds such as automobile bumpers. The movement of the axes is accomplished via joystick (analogue or digital options are available). The welding position can be determined down to 0.1mm and can also work in recessed areas. An ‘autoweld’ function allows for 360° swivel optics, so virtually no angle will remain hidden

Repair to threaded core by laser IN THIS example, extremely fine repairs needed to be made to a threaded core for a closure mould – a vital process as regards the performance of

the moulded closures. The location to be treated was filled in several operational phases by the Nd: YAG laser. New material from the

filler rods was applied in the course of each phase until the desired surface height was reached. Fusion occurs by focusing the laser beam on the surface. Before and after – Damage to the threaded core here required essential repairs, a process which was accomplished flawlessly with the OR Laser system, as you can see in the final, polished item on the right

 AUGUST / SEPTEMBER 2013


O R Laser’s technology has proved particularly successful in the battery sector, where the rapid joining of small and complex geometry components is a big advantage

in a thin boundary layer. This composition fulfills the metallurgical characteristics for mechanical, tribological, chemical and thermal stress. The transfer of heat to areas outside the welding point is prevented by the extremely short application of energy (millisecond), and hence reducing any effect the welding process may have on the metal. In view of the costs involved (factor x 8) to produce a new mould, repairs with the laser process represent a tremendous advantage

in cost savings. In some cases, even new moulds need to be repaired (possibly as a result of design defects or changes made to a design brief), so the simple effectiveness of the O R system makes it a useful option. Tool and mould making Whether producing or repairing, the laser can be operated efficiently in many ways in the tool and mould making sectors. This includes readjusting contours, corrections to

• OR LASER TECHNOLOGY GmbH was founded in 1997 and has established itself as a market leader in laser systems. With offices, partners and customers all over the globe, OR Laser has proven itself with outstanding success. www.or-laser.de

The weld can be extremely fine. In this case a metal component is being treated, whereas in the plastics and rubber sectors the process is typically used on injection and blow moulds

a tenth of a millimetre in accuracy or modifying the surface geometry of die cutting and injection moulding tools. Lasers can be used to harden tools and parts in areas subjected to particular stress, and can also be used for labelling and engraving which results in permanent marking.

• OR Laser is represented by Retecon of Johannesburg, one of South Africa’s longest established suppliers of machine tools, accessories, tooling, consumables and services to the metal working industry. Retecon was established in 1971 by Burkhard Herrmann and today operates branches in the main centres around South Africa. www.retecon.co.za

AUGUST / SEPTEMBER 2013 

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THE DESIGN FACTOR…

BY MIKE WYTHE, M DES RCA (ID ENG), INDUSTRIAL DESIGNER & LECTURER

Student product design FEATURE

manufacturing & profit springboard THIS year’s Afrimold exhibition illustrated once again that the plastics industry is in the doldrums. Speak to those that participated, machine exhibitors, mould makers, technology and software punters; you will be presented with the same old rhetoric and tails of resigned pessimism. “China is taking us to the cleaners, closely followed by India. There is very little work out there, we can’t compete anyway”, blah, blah, blah! Wake up! In the early 50’s as a kid in the UK I was totally unaware of the devastation and poverty stricken conditions that existed in South Korea, a country on its knees and at war with its neighbours in the North. Following the cessation of the conflict three years on and in the decades that followed, the South Korean economy grew significantly



and the country is now recognised as a major world economy. Two corporations accepted internationally as household names today – Samsung and LG - have been and continue to be major contributors towards the economic success of South Korea, with Samsung’s revenue equal to 17% of South Korea’s $1082 billion GDP and LG revenue topping of US$143 billion in 2012. One can ask how and what did they do to achieve this sustained economic turn-around? Some profitable growth was through acquisition, buying technology or companies. The main thrust of their move toward market dominance was by way of implementing a coherent product design and development strategy.

Initiatives were set in place to encourage a design ethos. Companies had their own in-house product development functions, tertiary structures were put in place to train and develop the creative skills – industrial design, graphic design and innovative engineering. Other less formal areas were also taken into consideration as potential platforms for new product development, specifically design competitions both international and in the Pacific Rim area. These companies recognised that the standard of product design and the diversity of creative thinking demonstrated through the work submitted by the students presented interesting possibilities for commercial development and market advantage. Two positive areas could be explored – the


product ideas put forward by the student could in fact form the springboard for a future manufacturing programme and the individual designers themselves could be taken on by the company as a value added addition to their in-house creative resources. What is there to learn from this approach? The value and contribution design can make to a business endeavour cannot be under estimated. Industrial design should be an integral part of any product development, manufacturing and market development team. PISA student design competition The one stand that generated considerable interest at AfriMold this year was the Plastics Institute of South Africa (PISA) sponsored student design competition. Students from TUT’s (Tshwane University of Technology) and UJ’s (University of Johannesburg) industrial design programme were set the challenge of solving problems relating to the recycling of plastic bottles. Within the domestic, informal collection and recycling sectors the perpetual problem

is the clumsy volume that empty plastic bottles take up prior to recycling. Through the application of their innovative and creative design thinking skills, the students were required to design a bottle crushing device. The product concepts presented by the students in response to the competition challenge were a high quality. The diversity of ideas offered were not only solutions to a ‘real time’ problem but also suggested a first step towards sustainable manufacturing, marketing and sales. Small and medium manufacturing companies would do well to take note of the product ideas developed by the students. To explore the possibility of taking viable concepts through to volume manufacture plus partnering with marketing and distribution organisation could realise a programme of profitable growth. Domestic and Sub-Saharan markets are hungry for products; we can sit back and allow cheap imports service this appetite, or our SMME’s can challenge these invaders place in our markets by developing, manu-

Lecturers directly involved in coordinating the design activities of students at TUT & UJ were, from left, ‘Wise man’ Mike Wythe (TUT), ‘Mr Energy’ Hein Dubery (TUT) and ‘The Thinker’ Angus Campbell (UJ’)

facturing and marketing a diverse range of South African produced products. The question is where do these products come from? The answer; the student design stand at next year’s Afrimold could be twice if not three times the size. On display would be an exciting range of prototypes, product ideas and competition winners. These concepts could stimulate local manufacturers and marketers towards a strategy of commercial development and profits.

• THE PISA DESIGN COMPETITION WAS SPONSORED BY PETCO, PLASTICS|SA & PISA




The road to knowledge - Dubai Knowledge Village is an educational free trade zone campus in the city of Dubai, which provides facilities for training and learning institutions to operate with 100% foreign ownership. There are over 400 institutions operating within it, which include universities, training centres, professional centres and HR companies

IF MONEY COULD BUY INNOVATION ... r scientists, engineers Middle East petrochemical industry provides critical mass of skilled polyme

BY DR NIALL MARSHALL

FEATURE

IN the 10th century Baghdad was the largest city in the world, the capital of the vast Abbasid Caliphate, home to Bayt alHikma, the House of Wisdom. The House of Wisdom, the largest library in the world, was the foundation for all the achievements made in science, medicine, mathematics and astronomy by intellectuals during the Golden Age of Arabic Science which lasted until Baghdad fell to the Mongols in 1258 CE. One engineer of that era, Al-Jazari, considered to be the ‘father of robotics’. (he built advanced mechanical automatons powered by water, for example, an accurate clock designed to look like an elephant). Unfortunately, since those heady times, the Middle East has not played an important role in technological advances. But if money can buy innovation, this is all set to change. Innovation required in the plastics industry Innovation is not the same as invention, and it is innovation that is required in the plastics industry. There are enough problems that can be addressed using plastics: more efficient use of water resources, alternative energy generation, improved agriculture yields and decreased food spoilage during transportation. And, most importantly, create well-paying jobs for the young populations of the Middle East. To understand how innovation can be nurtured it is useful to consider the successful Silicon Valley model which brings together a critical mass of skilled people, provides an environment where ideas can easily be generated, evaluated, funded, mentored and developed and where businesses can quickly be started and al AUGUST / SEPTEMBER 2013

lowed to fail as part of an adaptive learning process. For the plastics industry in the Middle East some of the requirements are easily accomplished, others remain a challenge. The petrochemical industry has invested in well-equipped laboratories in the Middle East providing the critical mass of skilled polymer scientists and engineers. This bodes well for innovation within the polymer producers. But achieving a similar critical mass of skilled people available outside of companies is more difficult as foreigners can only get residence based on employment, so the flexible pool of skilled people need to be nationals. There are significant government investments to develop such skills including the establishment of new universities such as the King Abdullah University of Science and Technology in Saudi Arabia and MASDAR Institute of Science and Technology in the U.A.E. as well as local campuses of leading international universities in Qatar and the U.A.E. The ‘clustering’ of competencies follows naturally from the development of industrial parks specifically for plastics converters such as the PetroRabigh PlusTech Park and the Jubail Value Park in Saudi Arabia and the Abu Dhabi Polymer Park planned to host one million tons per year of plastic conversion capacity. Need willingness to accept locally developed products But other challenges are less easily addressed. For example, there is an inherent suspicion of anything developed locally. In the Middle East, if it’s not developed, made, proven and sold elsewhere, preferably the USA or Europe, it’s not to be trusted. Unless there is a broad willingness to accept locally developed products, no culture of innovation can thrive. There is another critical aspect to successful innovation – the

10th Century engineer, Al-Jazari, constructed this accurate clock designed to look like an elephant and powered by water

willingness to try a lot of different things, to experiment, to make a lot of bets and to fail often, early and cheaply. With the number of business incubators, technology parks, research institutes and universities being established, business friendly policies being implemented and an increased focus on projects related to local issues, it is just a matter of time until innovation from the Middle East means more than 1000-year old designs for water powered automatons. NIALL CAN BE REACHED AT: NIALL.MARSHALL@EVERSPRINGME.COM Dr Niall Marshall was formerly based in Johannesburg where he worked with Sasol and Ciba. He subsequently moved to Bahrain in the Middle East and joined Everspring Middle East, one of the largest manufacturers of polymer stabilisers, and X-ponent Three, which supplies a complementary range of additives and pigments and provides technical and business consulting services


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Credit control for SMEs BY SAIJIL SINGH, LEAD ANALYST, COFACE, INTERNATIONAL CREDIT INSURER

Winning sales is half the battle; ensuring you get paid is the other half!

FEATURE

TODAY, maintaining and improving long-term financial health is the name of the game. To satisfy shareholders, positive cashflow combined with prudent investment, balanced growth, and cost control, is absolutely essential. Organisations should manage their risk through the implementation of intelligent credit strategies and work processes. In many organisations, the number of accounts in the receivables department is increasing, resulting in higher operational costs. And rising bad debt and write-offs are eroding margins. New customers, new orders from existing customers and new business opportunities are the adrenalin of every business. However, not all customers are the same, and a company’s organisational structure and customer strategies and procedures need to reflect these differences. The key to success is acquiring profitable, high-value customers and retaining them for the long term. Balance between risk and reward Organisations must strike the balance between risk and reward. Risk management, balancing profit potential and customer service with the risks involved in extending credit to a customer, is a critical part of managing the customer life cycle.

Information key to success of accounts As a company evaluates collections, it must determine the relative impact accounts receivables department The initial vetting of your debtor is essential to receivables have on the daily operations. circumvent fraud. An accurate way to ensure Simply, how much revenue is required to all the necessary information is obtained is operate the business and when is that revto use a comprehensive credit application enue required to meet obligations. form. Make certain you confirm the identity One of the critical elements to best of the company by validating phone, fax, manage accounts receivables is how much mobile numbers and e-mail addresses. While effort, time and expertise is required to doing this, verify the meet the comcompany’s address pany’s needs. If a The key to success and authenticate the balanced effort is is acquiring profitable, directors and owners placed on credit high-value customers names. risk management, and retaining them for Do credit checks on then collection of each new customer accounts receivthe long term. and conduct these ables should be checks regularly on existing customers. less demanding. These should include bank references, trade Credit limits or credit lines should be references and if possible perusal of their a functional tool that is located within the management accounts to allow you to mancompany’s accounting system as a trigger age your risk prudently. Assess if you need for potential over exposure based on the credit insurance to limit your risk. Using an incompany’s pre-determined credit risk tolerformation solutions company or credit insurer ance levels. to gain additional information, i.e. information Starting with a ‘soft call/correspondence reports and debtors visits, on-site visits to the programme, this then escalates into a more assertive in-house programme including sus- buyers operations are often needed for firsthand knowledge. pension of delivery or services to the comAnother mandatory requirement for any pany. If in-house collection practices have business is to use fully documented Terms not produced acceptable results, the use of outside collection agencies or attorneys may of Trade for Industry which amongst other conditions specifies payment terms, interest be the next step. Turnkey solutions to this percentages, includes a Retention of Title include credit insurance, although a credit clause and ensures it deals with disputes. insurer will also require that you implement It would also set out the different comeffective credit controls and policies. pliance issues including NCA, consumer protection, over-indebtedness, reckless credit and debt review. The customer must initial each page of this document; after all, the purpose is to protect your business from legal liability and to make debt recovery easier. The 5 C’s of credit A credit insurer can help ascertain the ‘credit worthiness’ of the debtor by determining the 5 C’s of credit imperative when assessing any debtor applying for credit: character, capacity, capital, conditions and collateral. Establishing the customers’ integrity, willingness to repay, credit history and whether the owner has ever declared bankruptcy is all part of discovering their character. A company’s capacity is determined by several financial factors which include:

 AUGUST / SEPTEMBER 2013


cashďŹ&#x201A;ow, payment history and contingent sources for repayment of the debt. If the company has had a â&#x20AC;&#x2DC;positiveâ&#x20AC;&#x2122; outcome on the credit check and sufďŹ cient cashďŹ&#x201A;ow to easily satisfy the payment terms, the odds are greater that you will approve an account facility. Unforeseen business difďŹ culties will always arise, posing the question whether the customer has sufďŹ cient capital to stay in the game. A positive net worth has the potential to offset insufďŹ cient cashďŹ&#x201A;ow. Funding, investments, shareholder commitment and leveraged debt is going to ensure that you feel more secure about approving account facilities. It is important to look at economic, industrial and company-speciďŹ c prospects and events that may occur which could have a signiďŹ cant effect on the debtors company. These might include rising raw material prices, an employee strike, increasing interest rates, etc. All these conditions need to be taken into consideration to achieve a balance between risk and reward. You can better control and protect against bad debt losses by insisting on collateral - any property owned by the customer that can be pledged for security. Typically if the business fails and the owner is unable to repay the debt, equipment, machinery, stocks and bonds and in some cases, even the ownerâ&#x20AC;&#x2122;s house and automobiles can be seized and sold to offset your losses. Many companies fail because insufďŹ cient time, talent or proper expertise is applied. Conversely, companies that maintain a properly staffed credit, collection and accounts receivables function can spend more time and effort in developing business opportunities.

www.cofaceza.com

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ABOUT COFACE The Coface Group, a worldwide leader in credit insurance, offers companies around the globe solutions to protect them against the risk of ďŹ nancial default of their clients, both on the domestic market and for export. In 2012, the Group posted a consolidated turnover of â&#x201A;Ź1.6 billion. 4,400 staff in 66 countries provide a local service worldwide. Each quarter, Coface publishes its assessments of country risk for 158 countries, based on its unique knowledge of companiesâ&#x20AC;&#x2122; payment behaviour and on the expertise of its 350 underwriters located close to clients and their debtors. In France, Coface manages export public guarantees on behalf of the French state. Coface is a subsidiary of Natixis. corporate, investment management and specialized ďŹ nancial services arm of Groupe BPCE. In South Africa, Coface provides credit protection to clients. Coface South Africa is rated AA+ by Global Ratings.

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WORLD NEWS

Coperion builds compounding line in Shanghai for Hexpol COPERION of Germany has equipped a special assembly facility for its modular compounding systems at its production site in Shanghai/China. This new 2000m² facility will help to cope with the increasing demand for modular compounding systems in the rapidly developing markets of the Far East. As is already the case in Europe and America, Coperion can now design and build any compounding line – conventional or modular – close to the customer in Asia. The Coperion site in Shanghai was built 16 years ago as part of its strategy of global presence. In the face of strong competition, Coperion secured the Swedish group Hexpol’s first order for the building of a modular plant in Shanghai for the compounding of thermoplastic elastomers (TPE). After assembly and commissioning at the Coperion facility in Shanghai, the system was delivered

to the customer, installed and put into service on a very short timeline. The core equipment of the modular compounding system is a twin screw extruder (ZSK) with 82mm diameter screws capable of a maximum output of 1800 kg/hour and suitable for different TPE formulations without any need for conversion. One of the most important user benefits of Coperion’s modular concept is the standard floorlevel installation of the ZSK 82 Mc18, permitting ready access during normal operation – especially for cleaning when changing over from one product to another – and also for maintenance and repair. • Coperion is an international market and technology leader in compounding systems, bulk materials handling systems and services.

www.coperion.com www.hexpolTPE.com

The compounding line built for Hexpol includes a twin-screw extruder (ZSK) with 82mm diameter screws capable of a maximum output of 1800 kg/hr and suitable for different TPE formulations without any need for conversion; here the system is shown at the Coperion site prior to installation at the Hexpol premises in Shanghai • The HEXPOL TPE group is a market leader in the development and production of customized thermoplastic elastomers and their composites. With production facilities in Europe and Asia, the group can serve worldwide customers in the medical, electronics, construction, automotive and consumer goods industries. The Group’s product portfolio comprises TPS (SBS, SEBS and SEPS), TPO, TPV, TPU, flexible PVC, cork compounds and masterbatches.

Graham Engineering acquires Welex GRAHAM Engineering Corporation (GEC), York, PA, has acquired the assets and assumed certain liabilities of Welex Incorporated (Welex), a leading provider of high performance sheet extrusion solutions. This follows the Graham Group’s acquisition of majority interest in American Kuhne (AK) in October 2012, furthering Graham’s investment in plastic processing tech-

nologies. The Welex manufacturing operations are expected to be integrated into GEC’s operations in York. David Schroeder, former President and CEO of Welex, has been appointed as the President of GEC, and Wolfgang Liebertz, current President of GEC, has assumed the role of CEO of the combined GEC/Welex organization.

The addition of Welex creates multiple points of synergy for the markets that GEC, AK and Welex serve: for customers worldwide, for supplier partners, and employees of the companies. GEC is gaining a global leader and trusted brand in Welex, as well as an experienced executive in Schroeder, who has significant experience in plastics processing technologies and in conversion businesses.’

New Maag pelletiser Maag of Switzerland has sold the first three units of its new PRIMO 200 E strand pelletizer model to Austrian master batch manufacturer Gabriel-Chemie GmbH. After a short test phase with a trial machine, Gabriel-Chemie found the decision easy: The PRIMO 200 E delivered outstanding pelletizing quality and high levels of user-friendliness, while its ease of handling for batch changing made cleaning and retooling much quicker, enabling significant savings to be made in production. The PRIMO 200 E received further plaudits thanks to its depositfree cutting head design, compact size and low running noise. • MAAG IS REPRESENTED BY JOESTEN INT’L, TEL: 011 915 3269; WWW.JOESTEN.CO.ZA 86 AUGUST / SEPTEMBER 2013

www.maag.com


Sumitomo Bakelite

AROUND THE WORLD

unveils SBHPP, establishes footprint in India New identity for high performance plastics business unit

Plastic bags ban extended

SUMITOMO Bakelite Co., Ltd. Group has unveiled its new identity for its High Performance Plastics Business Unit from April the companies forming the business unit will be known as SBHPP. The creation of SBHPP highlights the worldwide integrated sales and marketing network and global manufacturing capabilities offered by the manufacturer of phenolic resins, moulding compounds and circuitry materials. Customers of SBHPP will benefit from the worldwide available resources and expertise of the global leader in engineering thermoset resins and moulding compounds. SBHPP is represented by 20 companies spanning Asia,

China, Japan, Europe and North America. This includes the settingup of a company base in New Delhi, India, to further strengthen its support for customers in emerging markets. SBE India Pvt. Ltd. will include warehousing, marketing and a sales organization to serve customers’ needs in the region for plastics and associated materials.

Welex is the global standard in high performance sheet extrusion solutions. With over four decades of leadership, innovation and performance, Welex leads the industry with solutions installed in more than 3,000 customer locations in 69 countries. Welex innovations include co-extrusion and multi-layer methods that lead the industry as well as dozens of barrier lines installed globally. GEC is an industryleading supplier of extrusion blow moulding equipment and offers a complete range

of monolayer and multilayer blow moulding equipment and technology upgrades including: rotary wheel blow moulders for bottle sizes from 85 ml up to 19 litre packaging applications, shuttle machines for up to 10-litre capacity, reciprocating screw and shot pot machinery for lightweight HDPE containers, and single and dual head accumulator head industrial machines for up to 34kg shot capacities.

THE biggest city in the USA to ban plastic shoppers is now Los Angeles, with Dallas (Texas) debating the same action. The groundswell of opposition to the plastic shopping bag is resulting in factories specialising in this item going out of business. Procter & Gamble and McDonalds have now gone to oxo-biodegradable in their largest market outside the US – the Indian sub-continent. The inevitability of similar action being instituted in South Africa is causing concern, as it is recognised that environmental ministers at international conferences are very much inclined to emulate their peers. Mandatory use of oxo-biodegradable plastics is increasing in several countries, with Pakistan joining the UAE (Dubai/Abu Dhabi) in introducing their own oxo-bio standards in consultation with the European Commission (EU) in Brussels. There is no doubt that legislation is on its way around the world, and in South Africa the windfall of retailers income for charging for plastic shoppers could be wiped out if a complete ban is introduced.

www.sbhpp.com

www.grahamengineering.com

Smart opens plastics facility in India SMART Machineries and Moulds Pvt. Ltd has opened a new plastics extrusion blow moulding manufacturing facility in Western India. The new facility in Vasai, in the Thane district on the outskirts of Mumbai, will manufacture all sizes of extrusion blow moulding machines, including single and double station machines. Initially, the annual capacity is projected to be approximately 24 to 36 machines; however, Smart is planning to double their sales in the coming year. The new facility is strategically located near Smart customer’s manufacturing facilities in Western India, and near the coastline of the Arabian Sea, which will facilitate the shipment of machines for faster delivery. These facilities will focus exclusively on serving the growing demand for blow moulding products applications in their respective markets.

Dynamic year for Erema WITH annual sales in the region of €105-million Erema can look back on what has been a very encouraging fiscal year. After record-breaking results in the previous financial year this outstanding result in a year of consolidation has made a successful contribution to the continuing growth of the company. The global market leader in plastic recycling systems headquartered in Austria has been able to increase its turnover continually by an average of 10% over the last ten years. Consolidated group sales together with its subsidiaries Erema North America Inc. in Ipswich, MA and 3S GmbH in Roitham near Gmunden from April 2012 to March 2013 reached around €117 million. The new 2013/14 fiscal year also promises even more outstanding innovations from Erema for the plastic recycling market which will be presented at the K 2013 trade fair. The countdown for a new dimension in plastic recycling systems has thus already begun. www.erema.at

www.smartmmpl.com Shreeram Rane, MD of Smart Machineries and Hemendra Pradhan, technical director, with family and friends

AUGUST / SEPTEMBER 2013 


WORLD NEWS

Borealis acquires Total’s majority interest in Belgium’s Rosier SA BOREALIS has closed an agreement with Total to acquire its majority interest of 56.86% in Rosier SA. Rosier – listed on NYSE Euronext Brussels - is a mineral fertilizer manufacturer with two production facilities (Moustier in Belgium and Sas van Gent in the Netherlands) and markets its products in more than 80 countries worldwide. Rosier generated sales of €278 million in 2012. Borealis has offered €192 per share for Total’s majority interest. The gross dividend of €8 per share – approved

Moustier in Belgium and Sas van Gent in the Netherlands

by the AGM has been deducted from the price of €200 per share offered to Total. On the same date, Borealis also completed the acquisition of GPN SA. GPN SA is France’s largest nitrogen fertilizer manufacturer. Borealis is already active in nitrogen fertilizers in Central Europe, as well as in France following its acquisition of PEC-Rhin SA, today known as Borealis PECRhin SAS, in early 2012. These acquisitions are in line with Borealis’s strategy to grow its fertil-

izer business and to keep its number one position in Central and Eastern Europe and to become a leading producer in Europe. As Borealis acquired the 56.86% interest in Rosier, it will be required to launch a mandatory public takeover bid for the remaining outstanding shares. Borealis intends to proceed with a squeeze-out if it obtains 95% or more of the Rosier shares by the end of the bid. www.borealisgroup.com

Nampak Plastics unveils new site in Foston NAMPAK Plastics, the UK’s leading producer of plastic milk bottles, has opened its new fully operational plant at its Dove Valley Industrial Park in Foston, South Derbyshire. The multi million pound investment has been three years in the making and has enabled all bottling machines to feed directly into the dairy, making the Dairy Crest site efficient. The machines have also been converted into 2 litre and 4 pint Infini bottles - Nampak’s multi-award-winning lightweight bottle. Carl Jones, site manager says: “Being an in-plant bottle manufacturer provides a lot of environmental

benefits, such as reducing the cost of transporting empty bottles to dairies for filling. These changes mean we can really make the most of that facility and we’re delighted that it will also enable us to create more jobs in Foston.” Nampak Plastics recently achieved yet another global first and has trialled, tested and supplied the world’s first four-pint milk bottle containing up to 30% recycled high density polyethylene (rHDPE).

www.infinibottle.com

Carl Jones, site manager at Nampak Foston, with Mark Allen, CEO of Dairy Crest and Eric Collins, MD of Nampak Plastics

88 AUGUST / SEPTEMBER 2013

The design of the infini® bottle has been selected as the optimum solution to the lightweighting challenge. This has been achieved with a new design that does not force the material into each of the bottle’s corners. In reducing the distance to the corners of the bottle there is a considerable reduction in the weight of the material required. A further important element of the innovative design is the positioning of the handle at a corner edge of the bottle. Stored in the door of the fridge, the handle can therefore be positioned facing outwards making it easier for the consumer to remove the bottle. The bottles are made of HDPE and recycled HDPE. Every infini bottle contains up to 15% rHDPE. This recycled content will increase further in the future with a target of up to 30% by 2015. Infini can achieve weight savings up to 25%, whilst at the same time continuing to meet current performance specifications


SPE THERMOFORMING CONFERENCE: 9-12 September Atlanta, Georgia, USA: www.thermoformingdivision.com SAPPMA PIPES VII: 10 September Bytes Conference Centre, Midrand: www.sappma.co.za PLASTICS IN PHOTOVOLTAICS 2013: 10-11 September Hilton City Avenue, Philadelphia, PA: www.amiplastics-na.com/events POLYOLEFIN ADDITIVES 2013: 10-12 September Hotel Nikko, Düsseldorf: www.amiplastics.com/events PETNOLOGY EUROPE 2013: 16-17 September Munich, Germany: www.petnology.com INTERNATIONAL AVK CONFERENCE: 16-17 September ICS Int’l Congress Centre, Stuttgart: www.avk-tv.de COMPOSITES EUROPE: 16-17 September Messe Stuttgart, Germany: www.composites-europe.com

PHOTOS: LYNNE ASKEW

ARMSA ROTATION 2013: 4-5 September Kloofzicht Lodge, Muldersdrift: info@armsa.co.za

Karel Wilmot manning the impressive Retecon stand

KZN technology exhibition

hosts diverse line-up

DRINKTEC: 16-20 September: Munich, Germany: www.drinktec.com COASTAL CLEAN-UP: 16-21 September Various beaches: www.cleanup-SA.co.za EMO HANNOVER: 16-21 September Hannover, Germany: www.emo-hannover.de POLYURETHANES TECHNICAL CONF: 23-25 September Phoenix, Arizona: www.polyurethane.americanchemistry.com SMART PACKAGING CONFERENCE: 24-25 September Sheraton, Lagos, Nigeria: www.smartpackagingwestafrica.com MEDIPLAS 2013: 25-26 September NEC, Birmingham, UK: www.meetbirmingham.com

DIARY

WINDABA: 25-27 Sept: CT Int’l Convention Centre: www.windaba.co.za TUBOTECH 2013: 1-3 October Sao Paulo, Brazil: wynhoffU@messe-duesseldorf.de SPE TPO AUTO ENG POLYOLEFINS CONF: 6-9 October Troy Marriott, Detroit, USA: www.4spe.org MOTEK 2013: 7-10 October: Stuttgart, Germany: www.deprag.com PE2013 EXHIBITION & CONFERENCE: 8-10 October Messe Dresden, Germany: www.plastic-electronics.org THERMOPLASTIC ELASTOMERS 2013: 15-16 October Düsseldorf, Germany: www.tpe-conference.com K2013: 16-23 October: Düsseldorf, Germany: www.konline.de LUXE PACK MONACO: 23-25 Oct: Grimaldi Forum, Monaco: info@idice.fr RAPDASA 2013: 30 Oct - 01 November SANParks Golden Gate Hotel: www.rapdasa.org GLOBAL PLASTICS SUMMIT: 4-6 November Hyatt Regency Hotel Chicago, USA: www.GlobalPlasticsSummit.com CHEM EXPO AFRICA: 6-7 November Sandton Convention Centre, Jhb: www.chemexpoafrica.com PDA EUROPE: 18-20 November Atahotel Villa Pamphili, Rome: www.pda-europe.org TYRE RUBBER RECYCLING: 19-20 November Brussels, Belgium: www.tirerubberrecycling.com POLYMER FOAM 2013: 19-21 November Marriott Hotel, Hamburg, Germany: www.amiplastics.com/events (YIWU) INTERNATIONAL EXHIBITION: 19-22 November Yiwu City, Zhejiang Province, China: www.yiwuppp.com COMPAMED 2013: 20-22 November Düsseldorf, Germany: www.compamed.de THIN WALL PACKAGKING: 3-5 December Maritim Hotel, Cologne, Germany: www.amiplastics.com WIND TURBINE BLADE MANUFACTURE: 3-5 December Maritim Hotel, Dusseldorf, Germany: www.amiplastics.com/events EUROMOLD 2013: 3-6 December Exhibition Centre, Frankfurt, Germany: www.euromold.com  AUGUST / SEPTEMBER 2013

SolidCAM sets new standard for

CAM software at EMO 2013 SolidCAM will present its best and latest developments in machining. at EMO in Hannover, Germany, from 16-21 September, including its new SolidCAM SP2 version. The package has more than 100 enhancements across all its modules: iMachining 2D & 3D, 2.5D Milling, HSS, HSR/HSM, Sim 5X, Turning, Advanced mill-turn for multi-turret and multi-spindle machines as well as a new module, Solid Probe. www.solidcam.com

The package has more than 100 enhancements across all its modules


Allan Kinnear and Ronald Maheane manning the CRPM stand

Leonie Grove, Wenging Wu, Johan Venter, Grant Pattison and Hu Shunhui at the Haitian stand

THE KwaZulu Natal Industrial Technology Exhibition in July this year hosted a diverse line-up of exhibitors, new products and services! In addition to a host of diverse exhibitors,

the exhibition also proved to be a great networking opportunity and a platform to generate quality business leads. For the first time ever, a series of free seminars were also be held during the 15th biennial

Zelda Theron, Leon Moodley, Calvin Kuppusamy and Errol John on the Quadrant stand

KwaZulu Natal Industrial Technology Exhibition at the Durban Exhibition Centre. www.kznindustrial.co.za

Handling and assembly technology Over 1000 exhibitors and more than 35,000 visitors are expected to be at the 32nd MOTEK exhibition from 7-10 October in Stuttgart. MOTEK is the leading trade show for handling and assembly technology. Each year industry experts come together to catch up with the latest developments in assembly automation. Deprag Schulz GmbH, one www.motek-messe.de

of the exhibitors, will show systems for the assembly of components in a variety of applications. According to Jürgen Hierold of Deprag, the industry is showing clear signs of taking a fresh approach to assembly work, “moving away from a rigid full automation process towards more flexible worker-guided semi-automated workstations”.

www.deprag.com AUGUST / SEPTEMBER 2013 

International Trade Fair, No. 1 for Plastics and Rubber worldwide

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Big interest in K 2013 Düsseldorf Marked increase in demand for exhibition space: K 2013 is continuing where the thoroughly successful 2010 fair left off. All big-name companies of the international plastics and rubber industry will be taking part in their flagship fair in October. The demand for stand space has risen sharply, and numerous exhibitors want to make a bigger impact at the fair. All 19 halls of Düsseldorf’s exhibition grounds will be fully occupied. For Werner M. Dornscheidt, President and CEO of Messe Düsseldorf, the big interest from the entire sector confirms K Düsseldorf’s outstanding status. “K 2013 will give us a complete overview of the changing world market, and we can look forward to a multitude of impressive innovations. We know that many of our exhibitors are already working flat out on their new products and presentations. Düsseldorf will be a powerful source of inspiration for the plastics and rubber world!” Some 3,000 exhibiting companies will be participating in K 2013 from 16 to 23 October and presenting their offers from the fields of: machinery and equipment for the plastics and rubber industry; raw materials, auxiliaries, and semi-finished products, technical parts and reinforced plastics. “K makes the difference” – the motto of the upcoming event says it all. K Düsseldorf is a trend barometer and innovation forum for the entire sector, with the latest developments and optimized technologies being premiered here every three years. Company exhibits will be supplemented by a special show entitled “Plastics move the world”. This is where aspects of the theme of mobility will be taken up – everything from lightweight design in the construction of vehicles, aircraft and ships, and electromobility to individual mobility and modern leisure behaviour. Rosebank Travel are the Trade Fair Travel Specialists in South Africa with global access to cost effective accommodation for most Trade Fairs in Germany and around the world. As specialists in WORLDWIDE trade fair travel services, we offer BEST package prices including air tickets, affordable accommodation close to the fairgrounds (we are the ONLY travel company that charters HOTELSHIPS during shows), entrance tickets, comprehensive travel insurance, preferred foreign exchange rates (delivered to your work place) and many more... Rosebank Travel was established back in 1963 and has evolved from those early days of a Travel Agency to a highly sophisticated Travel Management Company. We have been doing travel for 46 years and probably know this industry as well as anyone in the country.


COMING UP PETNOLOGY EUROPE PART of Drinktec, the global beverages show, PETnology Europe in September caters specifically for the PET container manufacturing sector, where the main current focus remains on lightweighting. Presentations this year include ‘Better understanding of pallet stability as a major step towards further bottle weight reduction’ by KU Leuven and ‘Identifying Key Growth Trends and Opportunities for PET’ by Euromonitor International. The main sponsor of PETnology ‘013 is Sidel group. The event takes place on 16-17 September in Munich. www.petnology.com

SMART PACKAGING WEST AFRICA THE Smart Packaging West Africa conference, part of the Propak programme takes place at the Sheraton Hotel, Lagos, Nigeria, on 24-25 September. The show is intended to give insights into what role packaging plays in growing Nigeria’s consumer economy and will be of interest to suppliers wanting to participate in that market. www.smartpackagingwestafrica.com

Leader show for creative packaging LUXE PACK Monaco gathers together once a year the world’s leading specialists of packaging and materials serving cosmetics, perfumes, wine & spirits, watches, and fashion. This year the show will take place from 23-25 October at the Monaco Grimaldi Forum. Whether you are looking for new suppliers, a new technique, a trend, or simply wishing to establish business contacts in an exclusive atmosphere, LUXE PACK MONACO will present an even broader offering this year, with

nearly 400 exhibitors making these 3 days a highlight of the profession! In this photo, DuPont’s Surlyn® is used for a new decoration technology developed by DuPont and Oriol & Fontanel that allows for the encapsulation of textile fabrics such as lace in packaging containers for stunning effects. This technology will be on show at the Luxe Pack Monaco event www.luxepack.com

DIARY

GLOBAL PLASTICS SUMMIT A NEW, broad-based industry event called the Global Plastics Summit will convene decision makers and experts from every phase of the supply chain to address the opportunities and challenges of an anticipated ‘renaissance’ in the North American plastics industry – caused by the shale gas boom and the ‘re-shoring’ of business from the Far East – will take place on 4-6-November in Chicago. The North American plastics industry is on the cusp of a new wave of expansion, according to Nick Vafiadis, senior director of global plastics at IHS Chemical, one of the sponsors of the event along with the SPI (the USA’s Society of the Plastics Industry). “Manufacturers here are positioned to become global suppliers at a level we’ve not seen before,” said Vafiadis. “These are exciting times for the industry, and the Global Plastics Summit will be an unparalleled collaborative experience.” www.GlobalPlasticsSummit.com

TYRE RUBBER RECYCLING AN important event for the rubber recycling sector, relevant for the development of applications outside of the mainstream tyre market, runs from 19-20 November at the Le Chatelain Hotel in Brussels, Belgium. TRR will focus on current rules and regulations, the ethical and sustainability pressures and the latest technical innovations. Reuse discussion will focus on sports surfaces and asphalt blended products. There will also be presentations on pyrolysis. www.tirerubberrecycling.com

LIGHTWEIGHTING FOCUS AT EUROMOLD EUROMOLD, the World Fair for Mould making and Tooling, Design and Product Development, takes place in Frankfurt, Germany, from from 3-6 December. Based on the process chain ‘From design to prototyping to series production,’ it presents products and services, technologies and innovations and trends for the markets of the future. EuroMold promotes the formation of networks, partnerships and business relationships. There will be a special focus on lightweight construction and hybrid technology at this year’s show. www.euromold.com  AUGUST / SEPTEMBER 2013

EuroMold 2013 – Innovations, new highlights to mark 20th anniversary THE 20th anniversary of the EuroMold trade fair will be held from 3-6 December at the exhibition halls in Frankfurt. More than 1 100 exhibitors are expected, as well as more than 55,000 trade visitors. A variety of innovations, new systems solution and products, as well as a multitude of new special topics and events form part of the three-day show. Themes and innovations on show include lightweight construction, hybrid technology, rotation moulding, thermoforming and engineering services.

www.euromold.com


BOOKS

Analysis of EPS market GLOBAL demand development for expandable polystyrene (EPS) in the construction and packaging industries will slow down. Important factors are the recovery of the construction sector after the financial and economic crisis in 2008/09, state-funded programmes to improve energy efficiency, and increasing wealth and population in emerging countries. Average growth rates of 4.8% p.a. that have been generated in the previous eight years are unlikely to be reached again, but the international market research institute Ceresana nevertheless

expects consumption to increase at an AAGR of 3.8% in the next eight years. An expected market volume of more than US$15 billion in 2020 shows that the market for EPS is well worth a closer examination. Ceresana’s latest analysis of the global market for EPS provides indepth analyses on demand, production, and capacities as well as revenue and price development. It also offers a comprehensive overview of development expected for individual countries and regions as well as global market dynamics.

www.ceresana.com/en/Market-Studies/Plastics/Expandable-Polystyrene

Performance guidelines for food and packaging materials

From package to publication printing

SMITHERS Rapra Publishing has released “Food Industry and Packaging Materials - Performanceoriented Guidelines for Users”, providing detailed and comprehensible information about Quality Control (QC) in the industry. Different viewpoints are explained in relation to food companies, packaging producers and technical experts, including regulatory aspects. One of the most important steps is the comprehension of QC failures in relation to the ‘food product’ (food/packaging). The book also presents a detailed selection of proposals about new testing methods. On the basis of regulatory obligations in the EU about the technological suitability of food packaging materials, a list of ‘performance-oriented’ guidelines is proposed. Food sectors are mentioned in relation to products, related packaging materials, known failures and existing quality control procedures. This volume serves as a practical guide on food packaging and QC methods and a quick reference to food operators, official safety inspectors, public health institutions, Certification bodies, students and researchers from the academia and the industry.

PRINTING inks serve to circulate information and are used in nearly all products in our day-to-day lives. A quick glance suffices: a calendar on the wall, the newspaper on the table, a packet of biscuits, a catalog of goods or the wallpaper itself - all products have been printed in order to colour and decorate them or to provide us with information regarding the content. The importance of printing inks greatly exceeds the revenues of more than US$20 billion that were generated in this segment in 2011. The study provides a presentation and analysis of the market for printing inks – including forecasts up to 2019: revenues development as well as production and consumption volumes are analyzed for each individual region. Processing technologies of printing inks as well as influences exercised by various areas of application are examined in an indepth analysis. The study also provides profiles of the largest manufacturers of printing inks – clearly arranged according to contact details, turnover, profit, product range, production sites, and profile summary. Indepth profiles of 87 manufacturers are given.

www.polymer-books.com

 AUGUST / SEPTEMBER 2013

www.ceresana.com


#,!33)&)%$ !$6%243 Advertisers: Aug / Sept 2013 Alpha Plast 33 BASF 65 Berry & Spence 14 Cabletech Marketing OBC Carst & Walker 11 DemaPlastech 23 DH Polymers 36 Fukutomi 33 Gator Products 42 Haitian Huayuan 19 Hosaf 13 Jenowill 77 Karbochem 85 Leister Technologies 62, 63 Luigi Bandera 15 Masterbatch SA 05 MBT 17 Messe Dusseldorf 55 MGMW Trading 89 Miracle Mould 30, 31 Mould Base SA 44 NG Engineering 16 Nissei ASB 73 Orion Engineered Carbons 29 Paradigm Containers 78, 79 Performance Colour Systems 75 Plasquip 61 Plastamid 69 PlastiChem IFC Plastics SA 37 PMS Plastics 57 Polysaf 21 Protea Polymers IBC Rawmac 41 Relloy 67,83 Rosebank Travel 91 SABIC 39 Safrique International 45 SAPRO Insert SAPY Colours 93 Sasol Polymers 71 SES 59 Sun Ace 01, 03 Ultra Polymers 51 Welltec 35

We Buy and Sell Plastic Pallets 083 756 6897 www.premierpallets.co.za

FOR SALE 2 x Overhauled Extrudex Lab Extruders (25mm Screw Diameter) 1 x Graewe Vacuum Bath with Sprayers (3mtrs long), mounted Vacuum/Water Pumps included. For Pipe Extrusion up to 120mm Diameter.

THERMOFORMING, SHEET EXTRUSION, AND MATERIALS THERMOFORMING TECHNOLOGY SAVE 90% of your electricity use with GN!                        EXTRUSION TECHNOLOGY FROM AGRIPAK OF ITALY

1 x 3mtr Cooling Bath with Sprayers for Pipe Extrusion, mounted Water pump and Reservoir Tank included. 3 x 3mtr Stainless Steel Cooling Baths for Pipe or ProďŹ le Extrusion. 1 x Domino A300 In-line Inkjet Printer. Seller: Extrusion ProďŹ le cc Contact: Jens Kaiser 083 356 6330 | 043 7631345 expro@iafrica.com

PIPE EXTRUSION / RECYCLING PLANT Well established plant with six complete extrusion lines with all dies and pins. Two recycling lines with three granulators and all related tools. Ten years in operation with established clients. Owner retiring. Well trained personnel can be taken over. Price: R4 250 000.00 Call: 083 5000 651

COMPOUNDING CAPACITY AVAILABLE We can compound mineral powders into PP or PE Please call Alon on 021 521 2400

Mono & multi-layer extrusion lines for the production of:  !"    #  $ %      '    '(

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CONTACT <C?IK?BCB>  N;P PQ Tim Forshaw <=>>=?BCB>  Phil Hopkinson <=>F<IBCB>

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Are you going to K2013? Trade Fair Travel offer a travel package which includes: â&#x20AC;˘ Return airfare Johannesburg/ DĂźsseldorf â&#x20AC;˘ Airport transfer â&#x20AC;˘ Accommodation for 4 nights â&#x20AC;˘ Full breakfast daily â&#x20AC;˘ Travel insurance â&#x20AC;˘ DĂźsseldorf city map For more info visit www.tradefairtours.com or call 031 916 1414

Production Manager required for established manufacturer on the East Rand. At least 5 years Management experience in the plastics industry. Please forward CV to: plasticsposition@gmail.com

FOR SALE Small plastics manufacturing factory in Pinetown area Interested parties to contact: africarecycle@ gmail.com

GREENLAND OILS Michael Engels 072 125 4323

Reinette Jordan Email: reinette@jcl.co.za

Vacancy: Production Manager

Tel: (011) 903-8084 Fax: (086) 665-4323 email: mengels1@ telkomsa.net PO Box 1220 Walkerville 1876

To place a classiďŹ ed advert please Fax: 086 519 6089 or Tel: 021 712 1408 or E-mail: saplastics@iafrica.com www.saplastics.co.za

AUGUST / SEPTEMBER 2013




WITS team

Wits entry in Sasol Solar Challenge – the September 2014 event will be the fourth ever Sasol Solar Challenge and Wits is planning to compete using a brand new vehicle – the Parhelion – which is being built largely by the School of Mechanical, Industrial and Aeronautical Engineering

to compete in solar challenge Materials used in construction include carbon fibre composites THE heat is on for a team of students from Wits University who are racing to find sponsorship and finish building their ‘sun dog’ in time for the Sasol Solar Challenge.

SPORTS

Every two years, teams of students from tertiary institutions in South Africa and overseas design and build solar powered vehicles to compete in the Sasol Solar Challenge which covers 5 400km of variable South African terrain. The race is the longest of its kind anywhere in the world. In 2012 a Wits team competed in the challenge for the first time and finished fourth. The September 2014 event will be the fourth ever Sasol Solar Challenge and Wits is planning to compete using a brand new vehicle – the Parhelion – which is being built largely by the School of Mechanical, Industrial and Aeronautical Engineering. The name ‘Parhelion’ was inspired by a phenomenon of the sun which results

in the formation of a halo or circular rainbow around the sun. The common term for this phenomenon is ‘sun dog’. According to team leader Bradley Rautenbach, the Wits team wants to push the boundaries of technology and showcase the feasibility of renewable energy in the transport and energy sectors. The Parhelion is designed to optimise energy from sunlight using a semi-monocoque carbon fibre chassis, along with latest generation lithium-ion batteries, which will ensure that the car is extremely lightweight. Facts about Parhelion The solar car will travel at 100km/h using the same amount of electricity as an average hairdryer. It will be able to reach speeds of around 120km/h. The entire car will weigh around 170kg. Materials used in construction include carbon fibre composites.

World Solar Challenge – In October the World Solar Challenge will see teams departing from Darwin aiming to be the first to arrive in Adelaide, some 3000km to the south. Solar cars are allowed a nominal 5kW hours of stored energy. All other energy must come from the sun or be recovered from the kinetic energy of the vehicle. The elite Challenger class is conducted in a single stage from Darwin to Adelaide. Once the teams have left Darwin they must travel as far as they can until 5pm in the afternoon where they make camp in the desert wherever they happen to be.

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AUGUST / SEPTEMBER 2013

The amount of drag generated by the entire car will be almost the same as putting your hand out of the window on the highway. The batteries used in Parhelion are the same as those used in your cell phone (just more of them). The solar car will be 2m wide and 4.5m long – almost twice the length of a smart car. The car must be able to drive 5 400km in eight consecutive days. Only 23% of the sunlight is converted into electricity. www.witssolar.wix.com/home


PIPE

COMMODITIES (HD/LL/LD)

ADDITIVES

ENGINEERING

ELASTOMERS

The Protea Polymers Team offers innovative solutions to the plastics industry with the backing of world class products and industry professionals.

“more than just a chemical supplier”

Johannesburg: +27 (0) 11 842 3600 Durban: +27 (0) 31 450 5777 Port Elizabeth: +27 (0) 41 401 5500 Cape Town: +27 (0) 21 550 8232 www.proteachemicals.co.za

Fax: +27 (0) 11 842-3700


Be on target Injection moulding

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Visit us PROPAK Hall 5 Stand B6

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For further information contact: Pierre Jurgens: +27 (0) 83 276 1978 10 Staal Street Kya Sands Randburg

TEL: +27 (0) 11 704 0824

FAX: +27 (0) 11 462 2108

:(3,::,9=0*,:<7769;:<**,:::05*,  E-MAIL: info@cabletech.co.za

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