SA Plastics & Rubber Technology

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S A P LA S TIC S + R U B B E R TE C H N OLOGY

& R U B B E R T E C H N O L O GY www.saplastics.co.za

VOL 16 ISSUE 6 – DECEMBER 2018 / JANUARY 2019

 V OL 16 N R 6

Advanced Manufacturing Awards recognise & inspire SA’s manufacturers

D E C E MB ER 2018 / JA N U A RY 2019

Gold Pack Awards impress yet again! es ir u q c a p u o r g u a h Re ing MB Barter & Trad

Bottle Printers opens Cape Town plant

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www.saplastics.co.za

The Home of Size Reduction

LICATION PUB OF T (PCA) & N P TIO RN AF HE

HellermannTyton SA exports tools to Germany

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Capacity expansion at Concept in Howick

FrogzEggz mania! 31

Ocean Cleanup sets sail to Great Pacific Garbage Patch

40

Thermoforming parts – winning designs

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maritime-marketing-chen-hsong-a4-advert-Nov2018.pdf

1

2018/11/20

11:50

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By the way Publisher & Managing Editor: Martin Wells (martin@summitpub.co.za) Editor: Tessa O’Hara (tessa@summitpub.co.za) Editorial assistant: Andrea Morris (andrea@summitpub.co.za) Publishers assistant: Heather Peplow (heather@summitpub.co.za) Financial manager: Lisa Mulligan (lisa@summitpub.co.za) Designers: Jeanette Erasmus Graphic Design (jeanette.erasmus@lateraldynamics.co.za) 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: martin@summitpub.co.za Postnet Suite 42, Private Bag X16, Constantia 7848, Cape Town, South Africa Unit 8, Bergvliet Village Centre, Cnr Hiddingh & Children’s Way Roads, Bergvliet 7945

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@summitpub.co.za Printed by: Tandym Print, Maitland, Cape Town SA Plastics & 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 of Southern Africa

Association of Rotational Moulders of South Africa

Plastics Converters Association

PET Plastic Recycling South Africa

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Institute of Materials

This was no fishing trip – Delegates from Dow’s Packaging & Specialty Plastics business, participating in their ‘Operation Butterfly’ river clean-up in a joint-venture with PlasticsSA, examined a plastic litter boom on the Isipingo river south of Durban in October. And let’s just say, the Dow team got down and boogied and actually picked up plastics litter

‘Operation Butterfly’ sees int’l Dow team getting involved

PERSONNEL from Dow’s Packaging & Specialty Plastics business puts their backs into it when they participated in a river estuary clean-up at Isipingo near Durban in October. The Dow team included individuals from 11 nations, making it a truly international affair, and they quite literally experienced the downside of plastics litter during the ‘Operation Butterfly’ project (a joint venture with Plastics/SA) on 3 October. One of the first global material manufacturers to make their commitment to resolving the problem of plastics litter very clear, Dow staff, customers and friends and family undertook #PullingOurWeight beach and waterway cleanups at more than 50 locations across the globe during October – the aim being to bring attention to the issue of ocean plastic pollution. In South Africa, the Dow team led by Javier Delgado had been in Durban for a customer event, and then spent the better part of the next day familiarising themselves with the extent of the problem in this country. Apart from the estuary clean-up, they visited the Wildlands mixed material recycling centre in Cator Manor. Although the centre is close to the Durban CBD, conditions are challenging and the delegates could have been in little doubt about the difficulties faced by the collectors and those involved in the recycling activities at the centre.

Check mobile 200x a day, surely not?

A SURVEY in the United Kingdom found that the average woman checks her mobile phone about 200 times a day. It’s a relief that males don’t do the same, although that may remain for another survey, but the stat for the ladies is truly worrying: given an average waking day of 16 hours, that’s equivalent to checking the blasted device every five minutes. Bearing in mind that, presumably, the lesser percentage of this – if any – is likely to be work related, is there any point in employing a person involved in this activity? Is it any different in South Africa? I surely hope this is not the case at your company.

EWC: Disaster or re-industrialised economy?

THE proposed amendment of Article 25 dealing with the Land Restitution Act in the South African Constitution has South Africans talking. Many have concerns and questions about expropriation without compensation (EWC). Will EWC be a disaster or lead to a re-industrialised economy? “This question is especially salient for our younger South Africans, our young business people, who want to know how their business development plans might be affected by any amendment of the Constitution,” says Desiree Faber, marketing manager of the Rand Business Forum. “Our young business people and entrepreneurs are our future, not only in Randburg and the greater HAVE … IF YOU G TO SAY IN H ET Johannesburg area, but countrywide. They need to SOM de: if you si ht e brig inform themselves about any possible changes to the Look at th isdom to w of e gem us at have som to te business environment that might be the result of the ri ease w impart, pl frica.com ia s@ proposed amendment,” says Faber. tic saplas

2018/11/20 12:02


VOLUME 16 NR 6

Contents DECEMBER 2018 / JANUARY 2019

Find out more at www.saplastics.co.za

INDUSTRY NEWS

Gold Pack Awards impress yet again! Global experts at inaugural Advanced Manufacturing Show in PE Capacity expansion at Concept in Howick PlastiColors to distribute Milliken plastics additive concentrates in SA IDC’s focus on plastics sector bodes well for the industry Lovell Industries & Arengo Plastics get FSSC Food Safety Standard Rehau group acquires MB Barter & Trading HellermannTyton SA exports tools to Germany World Cleanup Day 2018 New from Progetto: automated carton packer The future of all things packaging at Propak Africa 2019

ENVIRONMENT

South Africans unite for a clean environment Ocean Cleanup sets sail to Great Pacific Garbage Patch Plastic-eating mushrooms

ASSOCIATIONS

IOM students look at key topics McLube Asia visitor points out features of effective release agents Waste not, want not Quality rather than quantity

DESIGN

Thermoforming parts – winning designs Student radio controlled car race & design competition

WORLD

Covestro supports sustainable urban development CFRP injection moulded composite replaces aluminium in oil control valve Machinery for innovative woven plastic packaging

EVENTS

Covestro success at Electra Mining Africa Varied solutions for the waste world at Wastecon Fakuma 2018

SPORTS

Trail Shreda mountain bike training aid

20 22 24 26 28 34 38

19

… for large injection moulds, extruders, rollers, autoclaves and other processing equipment

Temperature control units for water up to 90°C • RT 70 control system • Solid-state relay (SSR)instead of

21

40 42 44

heating contactor • Automatic phasechanger for pump direction (clockwise) • Alarm buzzer • Heating capacity 9 kW

NEW

• Cooling capacity 24-90 kW • Pump capacity 60 litres/min, 3.8 bar

Type 150 Smart 45 46 48 50

74

56 62 72 74

48

Temperature control units for oil up to 150°C • Controller RT61 PID • Outlet temperature max 150°C • Heating capacity at 400V 6 kW • Cooling capacity 28kW @ 140°C • Pump capacity 60 litres/min, 3.8 bar

76 78 80 84 92

• Simultaneous readout of temperature set-point and actual value • Clear arrangement of operating and indicating elements

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ON THE COVER New screen packs from Nordson Corporation effectively withstand the pressures of extrusion, providing maximum filtration and optimum melt flow while ensuring a longer working life and greater reliability than low-end screen packs on the market. Nordson introduced the screen packs at Fakuma 2018.

www.nordsonpolymerprocessing.com

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High-performance temperature control units

New, more efficient Type 90 Smart

6 10 16 18

REGLOPLAS

• Solid state relay (SSR) instead of heating contactor

• All components exposed to water are made of non-rusting materials, hence long service-life • Achieves estimated 24% reduction in rejects and 20% increase in productivity

JENOWILL SERVICES Contact – Willy Tschopp Tel: 021 551 7241 Fax: 021 551 7243 28C Lilly Park, Railway Rd Montague Gardens, Cape Town jenowill@iafrica.com www.regloplas.com

2018/11/20 12:02


Comment

Strike conflict

Within a very short space of time, convertors in trouble hotspots around the country managed to get private security companies to protect their premises. The alternative was running the risk of having your plant burned down, which in many cases would have led to business closure. Fortunately, no-one was killed

poses serious challenges for all in industry Urgent need to continue with skills growth of all

A

4 DEC 2018 / JAN 2019

T THIS moment, trying to make sense of whatever momentum may have been gained over the course of the year, it’s opportune to express thanks to the leaders of our industry, who in my view have done an outstanding job in spite of extremely difficult conditions.

The recent strike (and we hope it’s over by the time you receive this) by the National Union of Metalworkers has posed serious challenges for the industry and specifically its leadership. The NUMSA demand that the Plastic Negotiating Forum be disbanded was never going to be accepted by the Plastics Convertors Association, the industry’s employer representative body, but when this became apparent it set off a series of nasty intimidation events in which several plants and individuals were attacked. About the only good thing that can be said is that no one was killed, but it was close. As always in a conflict, there are two sides to the story (and then there’s the truth), but about the only guaranteed outcome of such a strike is that people will lose jobs. Some union members did stay out, after the strike was declared illegal, but were subsequently denied access on returning to the plants where they worked, in some cases resulting even in weeping. It was stressful for the employers to insist that these individuals remain out and take up the matter with their union bosses. But even in some of these cases employers have since relented. With such an apparent gulf between the employers

Gold Pack Award 2018 winner

Flip ‘n’ Roll – Koogan Plastics won the overall Gold Pack Award for 2018 for its ‘Flip ‘n Roll’ 20-litre container for Olympic Paints, with the novelty of the built-in fliptop lid opening and locking into position and becoming the painter’s roller tray. This is apparently not a global first, but absolutely an impressive achievement for Lenasia-based Koogan

THIS ISSUE

and unions, an agreeable solution does not seem achievable soon, but once the dust settles, one way forward may be to hold an imbizo at which the industry and union leaders can meet to try to reduce areas of conflict. In Africa, indabas such as this are one of the only mechanisms to resolve issues. It’s true that an ideological gulf divides the groups, but unless we start Imbizo for breaking down the barriers, things are not going to get industry and better. The key should be to union leaders continue with the skills and to try to personal growth of all people in reduce areas the industry and to develop a stronger industry that is better of conflict? suited to manage the demands and challenges we face. Issue of the year: The environment 2018 will most probably be remembered for the considerably increased pressure from environmental groups, specifically regarding one-way packaging and marine pollution. It’s understandable that people, even the manufacturers, may not see these issues as their responsibility, but we are going to need to come up with solutions to avoid loss of market share. Season’s greetings The Summit Publishing team wishes all our readers a peaceful and rejuvenating festive season. Martin Wells, Publisher Martin Well s, Publisher


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2018/10/23 1:00 PM


News

Gold Pack

impress

Excellent application, execution of innovative and creative design, marketing and technology to packaging in SA The annual Gold Pack Awards once again saw the South African packaging industry come together to recognise and share in innovative and exciting achievements.

“The Institute of Packaging would not be able to run this programme without the incredible support we receive from the industry - as entrants in the competition and as sponsors,” said Bill Marshall, one of the organisers of the glittering event. “Winning a Gold Pack award can be a major publicity-gaining moment, but there are other significant advantages too. Winning an award is undoubtedly a company morale booster; it provides creditability in the marketplace, a competitive advantage and a chance to shine internationally. All the Gold Pack winners - finalists and medal winners - are also eligible to enter the WorldStar contest organised by the World Packaging Organisation.” “Thanks to the sponsors for their confidence and belief in these awards and the importance of Gold Pack to the industry,” Bill added. Sponsors were Specialised Exhibitions

Montgomery/Propak, Nampak, Polyoak, Polyflex, PETCO, The Glass Recycling Company, Hi Tech Inks, MCG Industries, RPC Astrapak, and Packaging SA and Packaging & Print Media. The IPSA Gold Pack Awards are about promoting innovation, identifying the best solutions that have met South African and regional packaging challenges and ultimately maximising exports and minimising imports for the continent. The awards are also about benchmarking the local industry and keeping pace with global technological developments, as well as recognising outstanding design – which includes construction, graphics, convenience, product protection and ecological impact. “The judges looked for the excellent application and execution of any new, innovative and creative design, marketing and technology applied to packaging in South Africa. It is understood that the concept or technology may not necessar-

Gold Pack Trophy for 2018 and a Gold Award in Household and Rigid Plastics categories

FLIP ‘N’ ROLL

6 DEC 2018 / JAN 2019

CONVERTOR: KOOGAN PLASTICS BRAND OWNER: OLYMPIC PAINTS The judges had no difficulty recognising the excellence in the development, design and execution of the packaging for this entry. Conventional 20-litre round buckets of paint require the paint to be poured out into a tray for even application with a roller. This built-in flip top lid locks in the open position and becomes the painter’s roller tray. The square shape saves space in distribution and display. The buckets are stackable and can carry their own filled weight to a height of four buckets. The pack has a triple lock system and a tamper proof seal.

ily be original but it has been used in a manner that makes it exceptional or stand out. The judges looked for packaging that demonstrates the ingenuity and competitiveness of the South African Packaging Industry,” Bill explained. The scrutiny applied equally to the disciplines of design, marketing and technology, both individually and as a combination. The packs that win these awards should be examples of which the entire South African packaging industry would be proud.

Over al l Win ne r

STAR OF AFRICA

The number of entries into the new Star of Africa category was disappointing this year. However, the entries received did show that this category shows potential to recognise packaging produced outside of South Africa, but still on the African continent. We hope to see this category grow in future years, not only for packaging produced outside of South Africa, but also for packaging produced in South Africa specifically for markets in the rest of Africa.


Awards

yet again!

Considering all the criteria, this year’s judges offered knowledge in a wide range of disciplines as well as many years’ experience in the packaging and related industries. Judges include Andy Rice, Gunnar Sigge, Charles Muller, Ralph von Veh, Wendy Knowler, Annabé Pretorius and Kishan Singh All these deliberations and decisions were made over an arduous two-day judging process closely monitored and recorded by Bill. Here we only showcase award-winners using plastics. >>

Food

Rama Margarine Tub Range IML CONVERTOR: RPC MARCOM PLASTICS AND VERSTRAETE-IML BRAND OWNER: SIQALO FOOD This is the first metallic in-mould label tub in South Africa. This entry overcame the static electricity barrier in the metallic in-mould label process and allowed the brand owner to consolidate the branding between the margarine brick and tub.

BRONZE award

Montego pet Nutrition Field and Forest Range

GOLD award and Gold award in the Flexible Plastics category CONVERTOR: CONSTANTIA FLEXIBLES POUCH DYNAMICS AND NOVAFLEX BRAND OWNER: MONTEGO This new launch of a range of a family of five variants is presented with great graphics printed with a matt finish on a flat bottom pouch format. The packs feature a velcro closure which is the first velcro closure produced in South Africa for the pet food market. The pack’s graphics, printing, finish, format and velcro closure set the product apart while still delivering cost efficiencies for the brand owner. These flat bottom pet food bags are constructed from PET, metallised PET and LDPE laminate. The use of a velcro reseable closure instead of regular is a first for this size pack manufactured in South Africa. The double re-enforced Velcro and gusset enable the consumer to carry the bags by the gusset. The matte finish was used to reduce glare on shelf and breaks away from the traditional high gloss appearance, giving these bags a true point of difference. The bags were made using three webs to register during pouch making. The pouch has full open zipper instead of the normal transverse zipper used on quad packs allowing consumers easier access to the product. The quality construction, graphic design and printing creates a pack with appeal to both local and international markets.

GOLD award

Food

Lancewood Spreads Tub 200g CONVERTOR: DAIRYPACK TUBS / BRAND OWNER: LANCEWOOD HOLDINGS This is South Africa’s first tub with an in-mould label successfully applied to the tub’s concave sides and across the lid’s dropdown tab, which is designed to assist with opening. The advanced injection moulding enables true thin-walled sections to create a lightweight, uniquely-shaped pack which did not panel when hot-filled at 80°C. The lid design closes securely without affecting the foil seal.

SILVER award

Dola

Tira Coffee

Convertor: Africa Polysack Ltd Brand Owner: Eldoret Grains Ltd, Kenya

Convertor: Africa Polysack Ltd Brand Owner: Tira Coffee Ltd

BOPP film technology is new to this region; this is one of the first applications in the East African market. The empty bag can be used as a carrier bag. and plays a critical role in secondary advertisement of the packed product.

The gusseted 100g multilayer pouch is printed flexographically in eight colours. The high quality finish has attracted both consumers and other brand owners who are finding the enhanced visual appeal a perfect sales stimulant.

DEC 2018 / JAN 2019 7

GOLD award

Pet Food


News Beverages non-alcoholic

GOLD award and Silver award in the Rigid Plastics category

ELLA CAPPUCINO TUB 75ML

Polyoak Packaging (Pty) Ltd CONVERTOR: DAIRYPACK TUBS BRAND OWNER: STAR GATE INNOVATIONS (PTY) LTD The entry features a breakthrough innovation for consumers seeking premium quality cappuccino at a more accessible price point. This is South Africa’s first plastic in-mould label barrier tub suitable for retort at 118°C without distorting. This development extends shelf life of preservative-free, ambient espresso product to six months. The pack includes a uniquely shaped foaming device which is an ambigram of the brand’s logo, especially designed for easy insertion and maximum froth creation when shaken. The pack stacks compactly and securely on shelf, making it ideal for the hospitality and airline industries and able to replace cumbersome coffee machines.

Sustainabilty

SILVER award

NESTLÉ PURE LIFE 500ML CONVERTOR: NAMPAK BRAND OWNER: CLOVER This 500ml capacity bottle is the lightest PET bottle for its size in South Africa and is fully recyclable. The bottle weight was reduced to 12.5g from the previous 17g. This was achieved with a number of construction enhancements, including a change to the neck dimensions and the base design. The addition of nitrogen dosing ensured that the filled bottle would remain rigid and resistant to denting and damage during distribution and handling despite its lighter weight. The bottle also features a 1.4g closure.

Rigid Plastics

Bronze award

CROWN NATIONAL 100G SEASONING SPICE SHAKER CONVERTOR: T3 PLASTIC PACKAGING BRAND OWNER: CROWN NATIONAL This development is a culmination of three cleverly engineered components that perfectly combine form and function to produce a unique and practical shaker. The double-hinged cap is the first of its kind in the market and superbly meets the brief for a shaker that offers both a sprinkler and spoon sift function. The tear open safety seal ensures safety and freshness of the contents. This unit, combined with a custom fitted plug, ensures easy filling, longer shelf life, durability, stack-ability and easy consumer function

Bronze award

NESTLÉ HOT CHOCOLATE POUCH

CONVERTOR: CONSTANTIA FLEXIBLES POUCH DYNAMICS BRAND OWNER: NESTLÉ SOUTH AFRICA

Health & Beauty

GOLD award and a Silver award in the Flexible Plastics category

SATISKIN SHOWER GEL RANGE

Syndicate Graphics and AMKA

Convertor: RPC Astrapak and The Golden Era Group Brand Owner: Amka Products (Pty) Ltd Each variant of this range carries a strong individual image and concept whilst still binding to the overall brand architecture - not only across the fragrances but also across pack sizes. Each talks to a different emotional appeal but retains the style, look and feel of the original foam bath. The organic shape and curves of the foam bath are echoed in 8 DEC 2018 / JAN 2019

the ergonomic shape of the 400ml and 1 litre bottles. Fine details such as the two-tone caps, the visi-strip and carefully crafted typography and good use of the shrink film labels create a strong brand identity that keys into the overall ‘take your moment’ concept underpinning the brand.

An alternative to a rigid plastic bottle, this pouch reduces packaging and components, lessens landfill impact, reduces transport costs, matches the barrier properties required and improves on-shelf impact. The clear PET laminated to metallised PET and MLDPE is gravure printed in eight colours. The pouch construction stands upright with no sagging and presents wider display panels for on-shelf presence and communication. A customised zip closure eliminates clogging and endures repeated use.


wishing you a safe & happy

holiday

Phone. +27 11 704 0824 - info@cabletech.co.za 20 Amelia Lane, Lanseria Corporate Estate, Malibongwe Road, Lanseria

Cabletech half page ad '017 08.indd 86

2018/10/31 11:12


News

Inaugural African Advanced

a huge success! Examples of technological advancement world-wide at inaugural event

THE 4th industrial revolution is not science fiction. Experts from across the globe affirmed the reality, scope and scale of technological advancement worldwide at the inaugural African Advanced Manufacturing and Composites Show in Port Elizabeth from 6-8 November. This

was the biggest ever gathering of additive manufacturing, composites, robotics and VR/AR individuals and companies in the southern hemisphere. And what a show it was! Delegates, exhibitors, speakers and guests could not have imagined the scale and success of

The venue for the awards dinner was the spectacular Tramways Building in Port Elizabeth

Leslie Potgieter manned the Bodotex Composites stand which displayed the company’s innovative trenchless pipeline rehabilitation solutions, as well as epoxy resin technology, GRP liners for sewers spray relining systems for pipelines, pipe seals and more www.bodotex.co.za

The ‘Composites Cluster’ was officially launched at the African Advanced Manufacturing & Composites Show. Here the Chief Director of Space Affairs at the DTI, Nomfuneko Majaja, congratulates Andy Radford, Composites Cluster CEO, flanked by Nonkululeko Shinga, Chief Director Innovation & Technology at the DTI and Deon Engelke, Communications Director with Inkanyezi who helped organized the show

the show. The wide array of things to attend and see made it very difficult to choose – from futuristic virtual reality experiences offered by some exhibitors, to the inaugural awards evening, the choices and subject matter were phenomenal. Headlining the seminar speaker line-up for the show held at the Nelson Mandela Stadium & Conference Centre were German-based lightweighting giants Dr Michael Effing (Chairman of the Board, Composites Germany) and Dr Michael Emonts, award-winning CEO of the Aachen Centre for Integrative Lightweight Production (AZL) of RWTH Aachen University. Addressing aspects of Industry 4.0 and its potential to disrupt or change the normal course of business were Disruptas

The Advanced Laboratory Solutions stand where Marlon Koopman (product specialist) was on hand to answer questions about the company’s wide range of testing equipment. The company supplies laboratory and scientific instrumentation for sample preparation, mechanical testing, rheology, thermal analysis, microscopy, spectroscopy and surface science www.advancedlab.co.za

Shane Thackwray at the Graymaur stand which exhibited a range of the plastic components the company manufactures. Graymaur is a source for hgh performance thermoplastics services and also offers plastic welding and fabrication, for which they have an enviable reputation www.graymaur.co.za

Quinton Uren kept delegates informed at Jendamark’s exhibits, which were many and thought-provoking. Driven by Industry 4.0, the company is making its mark in global automation with a presence in Europe, Asia, Africa and North America. On display were examples of its capabilities in robot welding, metal 3D printing, a workstation demonstrating augmented reality, as well as a virtual reality area and 3D printing with plastics and composites www.jendamark.co.za

10 DEC 2018 / Jan 2019

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2018/11/19 16:37


Manufacturing Show The light entertainment provided at the awards dinner was reminiscent of a bygone age of elegance with songs from Ella Fitzgerald, Billie Holiday and so on

Many associations and industry bodies promote advanced manufacturing but generally there is a lack of integration and awareness of even our own capabilities, which are substantial,’” Radford said. The show featured four seminars and the 3rd International Conference on Composites, Bio-composites and Nanocomposites which ran concurrently with a two-day exhibition, demonstrations, factory tours and the first national awards for advanced manufacturing. “While manufacturing remains an essential part of South Africa’s economy, contributing around 19% of GDP, our efforts towards advanced manufacturing

www.africanadvancedmanufacturingshow.co.za

Founder Dr Harry Teifel, Mesopartner Director Dr Shawn Cunningham and Makerspace Foundation CEO Steve Gray. The event was supported by the national Department of Trade and Industry (DTI)and other industry bodies.Keynote addresses and panel discussions were incorporated into four half-day seminars addressing the themes ‘Strategy And Policy’, ‘Additive Manufacturing (3D printing), Automation and AI’, ‘Future Production Technologies’ and ‘Composites Materials of The Future’. South African Composites Cluster MD, Andy Radford, was the ‘visionary’ behind the show, which he says was “an essential stepping stone to uniting the country’s stakeholders around a common vision”. “The Advanced Manufacturing sector is highly fragmented in South Africa.

MC at the National Advanced Manufacturing Innovation Awards was Luvuyo Bangazi kept the audience entertained and on point!

in South Africa are highly fragmented, but we do have significant pockets of excellence,” Radford said. “The African Advanced Manufacturing and Composites Show not only brought all the key role-players and technology partners together towards a common vision, it also inspired emerging engineers. “Three-dimensional printing, lasers, automation, artificial intelligence and drones are exciting tools to encourage a new generation of engineers and scientists but we need to expose them and industry to these technologies and there is no time to waste,” he added.

Pretoria-based Eckardt du Plessis, owner of Industrial Composites and also Vice Chair of the Composites Cluster Board , presented his company’s range of polymer and composite product design and manufacturing solutions. The company specialises in structural fibreglass profiles with a range that includes angles, channels, flat bar, tubes of all shapes and FRP rebar www.indcomposites.co.za

Gideon Smith (marketing manager) and Chris Ford from S4, which offers turnkey automation and machine building solutions, from simple network installations to complex production line systems. The stand was a favourite with some delegates who were fascinated with the dexterity of the robot hand that was able to move small components around www.s4.co.za

NEWS AM SHOW.indd 11

Scott Bader’s Bruce Ray (Cape Town) and Thiru Kisten (KZN) were on hand to explain the advantages of the company’s Crystic polyester resin range and other Scott Bader products which aid in composite part fabrication. The company has been a pioneer in glass fibre composites since the 1940s, and their Crystic and Crestapol brands have gained a world-wide reputation for quality, reliability and innovation. www.scottbader.co.za

DEC 2018 / Jan 2019 11

Natural born innovator, trained engineer, teacher, artist and entrepreneur – Steve Gray is a dynamic voice in the world of technology and innovation. Founder of the MakerSpace Foundation, he is a master at demystifying technology and unpacking the human implications of our rapidly changing world. Steve offered delegates and visitors to the show an entertaining and insightful look behind the tech curtain, unveiling a picture of the future and engaging listeners from all walks of life www.themakerspace.co.za

2018/11/19 16:37


News

Awards recognise & inspire SA’s manufacturers Gelvenor Textiles awarded most innovative with world-first product NATIONAL awards officially recognising innovation and excellence in Advanced Manufacturing were made for the first time in South Africa at the African Additive Manufacturing & Composites Show held in PE in November. The National Advanced Manufacturing Innovation Awards, hosted by the DT and the national Composites Cluster, were opened to all companies operating in the advanced manufacturing field, including 3D printing, robotics, automation, AI, laser cutting and etching, CNC machining, software, big data, IOT and composites. Gold, Silver and Special Mention Awards were made to 25 organisations in six categories. Composites Cluster MD, Andy Radford, said the awards would play a key role in advancing the country’s advanced manufacturing agenda. “As we push to consolidate and develop our manufacturing strategy, it is essential that as a collective, government and private sector stakeholders identify, promote and reward innovation in the advanced manufacturing and composites industry.”

12 DEC 2018 / Jan 2019

Composities Floating Trophy for displaying innovation

fabric engineering company, Gelvenor Textiles has been an industry innovator since 1965. Products include a variety of aeronautical textiles, industrial fabrics, protective workwear, technical apparel and high performance outdoor textile fabrics. www.gelvenor.com Sandy Stewart of Gelvenor Consolidated Fabrics receives the Gold Award for Innovation in Composites from Acting DDG of the DTI, Stieneke Jensma

Gelvenor Textiles for its solution, a global first, using high tenacity steel threads sewn into the tarpaulins covering delivery trucks. This is then coated with PVC, making the tarpaulin virtually impenetrable from thieves trying to cut through the tarpaulin. Gelvenor put forward their cutresistant composite textile developed to form the base of truck tarpaulins. Every year, the trucking industry faces massive losses from cargo theft due to tarpaulins being cut to steal the goods inside. Gelvenor’s multi-layered fabric is designed for safety at base level, incorporating angled steel fibre to ensure that the tarpaulin is resistant to horizontal or vertical slashes or cuts. “This notable achievement has spurred Gelvenor to continue developing advanced textiles with innovation designed into the fabrics at a fibre level. We would like to thank everyone involved in the African Advanced Manufacturing and Composites show,” said Dicky Coetzee, Gelvenor CEO. As a leading textile manufacturer and

Gelvenor’s award-winning cut-resistant composite textile developed to form the base of truck tarpaulins Gold, Silver and Special Mention Awards were made to 25 organisations in six categories

NEWS AM SHOW.indd 12

DTI director Nontombi Marule (Innovation & Technology Policy) who helped to present the awards, and Composites Cluster MD, Andy Radford share a moment together before the first national awards for advanced manufacturing … apparently Andy made the awards presenters rehearse, rehearse and rehearse …

Scholarly impact in advanced manufacturing – GOLD AWARD

Central University of Free State for its rapid prototyping and manufacturing of patient specific titanium printed facial implants. Working with state hospitals and doctors, the high tech work of the University has transformed the lives of hundreds of patients with muscularskeletal irregularities. The Centre for Rapid Prototyping and Manufacturing (CRPM) is located at University and was established in 1997 as part of a research initiative. At that time, Additive Manufacturing (AM) also commonly known as 3D printing, was in its infancy worldwide. Through the foresight of the founders of the CRPM, a laser sintering machine was imported from Germany for research at the Faculty of Engineering. >> One of the most eye-catching outdoor exhibits was this rare Zagato AC 378 GT, a V8-engined, two-door sports coupé designed by the Italian design company Zagato and developed and built in South Africa by Hi-Tech Automotive in their Port Elizabeth factory. Weighing only 435kg, the car’s bodywork is shaped entirely from vinylester composites

2018/11/19 16:37


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2018/06/04 12:47


News

Awards recognise & inspire SA’s manufacturers << This was the fifth machine in the country. It was soon realised that the equipment could benefit industry by offering a service in rapid prototyping. This would fulfil one of the missions of the university which is to introduce new technology to the South African manufacturing industry. The centre received ISO 13485 certification for 3D printing of medical devices making it the first centre in SA and Africa to receive this prestigious certification for an Additive Manufacturing Centre. www.crpm.co.za

Industry advancement in advanced manufacturing – GOLD AWARD

Vaal University of Technology – Vaal University of Technology, earned a Gold Award for Industry Advancement in Advanced Manufacturing for the VUT Science and Technology Park. The Park is an ambitious Additive Manufacturing project with cross-sectoral industries, working within communities via the collaborative program for additive manufacturing (CPAM). Small and big industry has access to technology, including Laser Sintering (LS), Fused Deposition Modelling (FDM) and polymer powder-based binder jetting, as well as fibrereinforced polymer based additive manufacturing, at the Park.

Most promising start-up or newcomer – GOLD AWARD

Innovative Dental Solutions for its impact detection mouthguard. Ralph Meintjies, a dental technologist from Port Elizabeth, started by using recycled EVA and a George Forman toaster before achieving his final prototype.

of carbon fibre, fiberglass and expoxy each year. Since 2010 they have won a podium finish in every World Gliding Championship, with gold awards in the 2017 Open and 18m classes. With M&D Flugzeugbau in Germany now further strengthening the team, the company has become a force to be reckoned with! www.jonkersailplanes.co.za

Import replacement – GOLD AWARD

14 DEC 2018 / Jan 2019

Jonker Sailplanes – this international award-winning glider manufacturer exports 90% of their product and employs 16 engineers and 110 employees. They use 10.5 tons

Scholarly Impact in Advanced Manufacturing Rubber Nano Products for its polymer based vulcanization enhancement.

Import Replacement Advanced Fibreform for working with VWSA to manufacture a carbon fibre robotic arm. Aerosud Aviation for their insulation blankets for cargo lining for the Airbus A400. These were previously imported from Canada but are now produced locally by Aerosud Aviation at little over half the price. www.aerosud.co.za

Representatives from Jonker Sailplanes, Aerosud, Advanced Fibre-form and Custom Works Composite Engineering received Special Recognition Awards for Innovation in Composites

NEWS AM SHOW.indd 14

Composites Floating Trophy for Innovation AAT Composites for its polymer 3D printed autoclave moulds for use in the aerospace industry.

Industry Advancement in Advanced Manufacturing Lonmin PLC/Western Plainum Refinery for its development of 3D printable platinum powder. Adient Pasdec for its production of automotive seas and mechanisms using laser welding and robotics.

www.vut.ac.za

Export proficiency in advanced manufacturing – GOLD AWARD

Silver Awards in each category went to:

Most Promising Start-up or Newcomer Alvarita, a food safety company which uses Greentest to establish the nitrate levels in fresh produce, meat and water. The company is currently developing an IoT radiation testing solution.

Dr Raymond Patel (former CEO of merSETA), Ester van der Linde (merSETA), Prof Gerrie Booysen (Central Uni of Technology, Free State) and Dr Shawn Cunningham (Mesopartner) at the Inaugural African Advanced Manufacturing and Composites Awards

2018/11/19 16:44


Attend free daily seminars

12339 - PROPLAS 2019 VIS 210X297 SA PLASTICS PATHS.indd 1

Network with suppliers & service providers

2018/11/14 1:20 PM


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News

SAPRO launches Design for Recycling Indaba

SAPRO, the Plastics Recyclers Organisation, has partnered with WWF to launch the inaugural South African Design for Recycling Indaba. The Indaba builds on the shared vision of the partners to respond to the global shifts in single-use plastics towards more sustainable packaging solutions and design innovation to facilitate recovery and recycling thereof. It aims to promote awareness and foster producer, brand owner and retailer commitment to sustainable packaging design. The Indaba takes the format of two workshops, hosted over two days on 13/14 March as a part of Propak Africa 2019. Propak Africa is Africa’s largest packaging trade exhibition attracting over 15000 local and international visitors. Speakers lined up include WRAP, WWF, the Ellen MacArthur Foundation and more. www.plasticrecyclingsa.co.za

Safepak, one of oldest Cape film businesses, exits scene

SAFEPAK, one of the Cape’s longest established film and bag manufacturing businesses, has shut. Set up in the 1970s in Lansdowne, Cape Town, to manufacture printed consumer flexible packaging – in particular the patented ‘Minigrip’ bank bag, Safepak underwent a major transition in 2006 when the company was sold in a 100% BEE deal. The main shareholder was Nozala Investments, a broad-based women’s investment company in operation since 1996. But with the new managing director based in Johannesburg, momentum at the manufacturing unit at Ndabeni in Cape Town slowed. Then, earlier this year, a turnaround specialist was appointed to revive the operation but, as other who had experience of the person concerned feared, the reverse happened. The doors shut at the end of October, with the only good news appearing to be that all staff were paid off. 16 DEC 2018 / JAN 2019

Capacity expansion

at Concept in Howick Edwards Bros up service to Midlands customers

THE Edwards brothers of Concept Plastic Moulding of Howick, KZN, have recently commissioned their biggest blow moulding machine yet, a True Easy system from China which can manufacture containers up to five litres. Part of a capacity expansion project, Concept also recently commissioned two new Yizumi machines (120 and 260-ton systems), giving it the opportunity to increase production of both preforms and closures. An 8-cavity preform mould for 5-litre PET containers was also supplied as part of the project by Dave Moore of Mouldbase SA, the Yizumi agent. Both toolmakers, the brothers – Nick

and Jonathan – previously operated separate toolrooms in Maritzburg, with a bit of injection moulding on the side. But five years ago they decided to start Concept and moved from Maritzburg up to Howick, where the business was set up in 2013. Concept is an integrated converting operation offering injection and blow moulding, with one of the main advantages being that they can make their own moulds. This did prove to be the case and they were soon moulding for a number of brand companies. The early reward for the brothers was a Gold Pack Award in 2015 for the ‘Hey Brew’ caffe latte flavoured milk

The early reward for the brothers was a Gold Pack Award in 2015 for the ‘Hey Brew’ caffe latte flavoured milk beverage for Woolworths.


Preforms are produced on a new 260-ton Yizumi injection moulding machine. Both the machine and mould were supplied by Dave Moore of Mouldbase SA of Durban

Concept’s good – Brothers Nick and Jonathan Edwards of Concept Plastic Moulding of Howick, KZN, are happy with the company’s new Yizumi 260-ton machine, which gives them the capability to manufacture preforms for 5-litre containers on site. Both toolmakers, the brothers moved from Maritzburg up to Howick and started Concept there in 2013

beverage for Woolworths. The cup featured a nonspill fixed lid, allowing the coffee to be heated and consumed directly from the pack. The design has since been changed, with Concept managing the design transition too. Concept has, possibly wisely, skirted the

Hi 5! – The Edwards brothers, Nick and Jonathan, of Concept Moulding with the new True Easy blow moulding machine commissioned at their Howick plant recently. Concept is using the machine for the production of 5-litre PET containers

challenge of building multi-cavity preform moulds – that being the preserve of a number of high specialised toolrooms in China, particularly. The positioning in the KZN Midlands town has proved more suitable as it’s enabled Concept to be in closer proximity to its main clients. DECEMBER 2018 / JANUARY 2019 17

Dave Moore: 083 675 8325 E-mail: dave@mouldbasesa.co.za Annette: 083 788 1565 E-mail: annette@mouldbasesa.co.za

YIZUMI LAUNCHES THE NEW A5-S MODEL FEATURING THE FOLLOWING UPGRADES

• Linear guides on injection unit • Centralised grease for injection unit • Euromap 67 robot interface • New high-speed Mirle MK500 controller • New screw designs across the range allows for better mixing and faster plasticising

MOULD BASE SA

Contact us for a brochure pack to be sent to you

www.injectionmachine.co.za Injection Moulding and Ancillaries Supplier


News

Bottle Printers opens Cape Town plant

Bottle Printers Cape Town MD Laurent Moret at the new plant in Epping

New plant is joint venture with print expert Laurent Moret

BOTTLE Printers of SA, one of the country’s top specialised container printers, has opened a new factory in Cape Town, enabling it to expand services to the Cape market.

Bottle Printers Cape Town is a joint venture with Cape-based print fundi Laurent Moret, who has over 20 years’ experience in container printing. Centrally located in Bofors Circle, Epping, the plant went into operation late in 2017. “We brought our expertise and equipment together in September last year and the operation has gained momentum steadily,” said Laurent. Over 30 people are now employed at the new company. Now, a year later, it is running silkscreen printing on a wide range of plastic containers, mainly for the cosmetics, hair care, DIY and detergent markets as well as, most recently, containers for the chemicals sector. BPCT is also seeing an increase in demand from the glass sector, where it prints with ceramic inks. At this stage the Cape plant does 18 DEC 2018 / Jan 2019

NEWS PLASTICOLORS.indd 18

not offer pad printing or foiling, so jobs with these requirements are printed by the BPSA plant in Kyalami. According to Laurent, even though transport to Gauteng and back is obviously a factor, it is feasible and practical to offer this option to its customers. An alternative is for the containers to be manufactured in Gauteng, printed there and shipped down to the Cape. “We believe there is a great market for direct printing in Cape Town and surrounding areas and that Bottle Printers can fill the gap where other printers can’t,” added Laurent. The new plant also offers ‘high stove’ enamel ink printing on to glass in volume, which is the first of its kind in the region when it comes to third party printing. In short, if it is possible, with the expertise at hand, Bottle Printers prints it. www.bottleprinters.co.za

2018/11/19 16:49


TOGETHER. Creating Creating PlastiColors to distribute innovative solutions Creating solutions for polypropylene. innovative solutions Milliken plastics additive innovative

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Thorough understanding of value, workings of Milliken’s nucleators & clarifiers

MILLIKEN has named PlastiColors the official distributor in South Africa for its clarifiers, nucleators, UV absorber concentrates and ClearTint concentrates. The agreement took effect on 1 August 2018. PlastiColors has actively developed markets for Milliken’s products over the past five years. PlastiColors has a thorough understanding of the value and workings of Milliken’s nucleators and clarifiers, enabling it to effectively sell the benefits of those products to its clients. Additionally, Carolyn Kellock, PlastiColors’ Technical Manager, worked as Territory Manager for Milliken’s South Africa office from 2013 to mid-2017. This further strengthens the knowledge base at PlastiColors as regards the use and potential further development of markets for Milliken’s range of products. Kellock feels the two firms are a good fit: “Both PlastiColors and Milliken are family-owned businesses that share a passion for technology and creating new solutions for developing markets. We believe this will be a strong, long-term relationship and that together our companies can continue to grow Milliken’s valued products within the South African market.” Milliken will continue to maintain its own office in the country, from which it provides all necessary technical

support and solutions. The company is pleased to be bringing global innovations to South Africa and across the African continent. About Milliken Milliken has been solving everyday problems with innovative solutions for more than 150 years. Our research, design, and manufacturing expertise reaches across a breadth of disciplines including specialty chemicals, floor covering, and performance and protective textiles. An unwavering commitment to ethics guides our work to redefine how we add strength and protection to products, how we infuse vibrancy and colour into our surroundings, and how we care for the environment. For us, success is when discoveries made within Milliken help us all have more meaningful connections with the world.

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DEC 2018 / Jan 2019 19

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NEWS PLASTICOLORS.indd 19

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2018/11/19 16:50

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News

Just one area in which the IDC is focussing on the downstream plastics industry is the introduction of new products, materials and processes

IDC’s focus on plastics sector

bodes well for the industry

www.idc.co.za

Willing to take risks in appropriate project development activities

THE Industrial Development Corporation (IDC) views the manufacturing of plastic products (the downstream plastics industry) as central to the development of the very important chemicals value chain. It is a crucial element for the new dawn of the South African economy with specific reference to its links with the rest of the economy, its role in the circular economy and as a root-industry for the ‘fourth industrial revolution’. With more than R1 billion exposure and commitments to the downstream plastic sector, the IDC has experienced the challenges faced by the sector. These include, amongst others, the input polymer cost, outdated machinery and low investment rates, skills shortage, poor public transport infrastructure and unreliability of electricity. However, the IDC supports the industry in progressing towards its development goals through the facilitation of an enabling environment, project development as well as its risk/development finance. It would like to facilitate a virtuous circle of investment, increased efficiency, and economies associated with throughput and scale reducing average fixed costs and improved competitiveness. Its focus areas in the downstream plastics sector are: • Enhancing competitiveness through improving productive capacities, technologies and efficiencies. This could be obtained by investments in the upgrading of equipment, applying new technology, use of new materials and designs as well as increased use of recycled material input. • Introduction of new products, materials and processes. Investigate the manufacturing of new/substitute nonpackaging construction-related products for use in projects or industrial/infrastructural initiatives; • Identify manufacturing opportunities for new plastic materials including composites • Investigate the introduction of new production processes such as advanced manufacturing. • Reduced import propensity of plastic products. Determine local intermediate demand opportunities that emanate from industrial policy initiatives or priorities such as the DTI’s Industrial Policy Action Plan;

Identify and invest in competitive import-replacement opportunities that can stimulate local manufacturing. • Increased recycling capacity. Explore greater use of recycled plastics in production processes through investments in the value chain; • Support initiatives that will lead to the optimisation of an efficient recycled-plastics value chain. The IDC’s value proposition is based on balancing financial and developmental objectives and its in-depth understanding of the downstream plastic products sector. It is therefore willing to take risks in appropriate project development activities, be exposed to equity risk in merituous investments, not be driven by security and be interested in protecting industrial capacity through the tough times of the commodity cycle. Leverage private and government sector support The IDC has a long-term developmental view and customises funding to the cash flows needs of a specific company (that could include the necessary capital and interest repayment holidays). It also can leverage private and government sector support for our client base. The IDC is mandated to facilitate industrial capacity growth and development in the South African economy. The main outcomes of its interventions in key manufacturing value chains are to create sustainable employment, promote entrepreneurial development, facilitate transformation and inclusiveness, improve spatial equity and support sectoral diversity and localisation. Its development mandate also allows it to invest in plastic products manufacturing activities outside the borders of South Africa. The IDC is therefore keen to engage with South African companies that would like to geographically spread operations to the rest of the African continent or facilitate the creation of value chains across borders. Going forward the IDC will continue to focus its funding efforts towards opportunities to support companies in the plastics products value chain and are keen to further engage with the sector to continuously refine its interventions and assistance to create a prosperous, internationally competitive and inclusive sector.

20 DEC 2018 / Jan 2019

NEWS IDC.indd 20

2018/11/19 17:06


New static neutralisation system for injection moulding market Sareltech introduces revolutionary system from Fraser extremely economical and above all highly effective.” The combination of powerful, pulsating air and static elimination gives Roto-Clean an advantage over alternative products. It will set new cleaning standards in environments that require strict quality control, or when products move on to secondary processes such as labelling or decoration where they must be dust free. The device uses less air delivered at a lower pressure than airknives, delivered at a greater intensity of ions per cubic centimetre. An air bar revolves at 60 revolutions per second using a patented centrifugal control powered solely by air. Air from two nozzles is ionized as it passes over a circular static eliminator. The pulsed airflow contacts the product up to 240 times per second, blasting away dust from various angles including crevices. The nozzles require no additional power source. “The system removes dust and other contaminants and also ‘neutralizes’ the products to prevent attraction of the contaminants and so ensures a perfect surface for painting, printing or label application or other applications. Previously anti-static air bars or jets were used but they could not always clean all surfaces due the the product shape, but the Rotoclran is more effective due to its unique design,” added Sarel. Roto-Clean is shockless and suitable for tough industrial processes, powered by the Fraser HP power unit. Roto-Clean is available in 112 and 178mm diameters, with operational pressure from 1 to 3.5 Bar. • Fraser is represented by Sareltech

The system consists of a dual rotary nozzle driven by a patented centrifugal control integrated into a circular static eliminator. According to Sareltech, the SA agent for Fraser, the Roto-clean system is well suited for used in injection moulding applications

www.sareltech.com www.fraser-antistatic.com

NEWS IDC.indd 21

CONSIDERABLE quantities of smoke and mirrors appear to surround the demise of the leading businesses DPI Plastics and Karbochem during the course of 2018. Karbochem, a manufacturer and supplier of various synthetic rubber materials including polyisoprene, operated a manufacturing unit at Newcastle in KZN and head office in Johannesburg; it was liquidated in the first half of the year. Even the company’s sales manager was taken by surprise by the announcement. Even more surprising was the news that a relative of one of the directors was already selling rival imported material before the closure was announced. DPI, established in 1987, was for long the leader in both HD and PVC pipe manufacture in South Africa. It was also well represented in southern Africa and had a sales outlet in Mauritius. But a series of questionable management decisions from parent company DAWN appears to have had negative repercussions: it bought into the KZN pipe companies Sangio (PVC) at Cato Ridge and Swan (HD/PP) in Durban, but both deals flopped. The Sangio production manager left in 2015 and set up in competition, taking a large chunk of turnover with him. Sangio later stopped production and its machinery was moved to an expanded PVC pipe plant at Roodekop in Joburg, which was recently shut too. And, earlier this year, it sold its share in Swan back to the original owners in what may have proved a costly U-turn. It is possible that management of group manufacturing businesses may be subjected to factors which outsiders are not aware of, leading them to adopt unconventional strategies. At DPI in Cape Town, staff numbers have been whittled down from over 100 to about 10, and it now appears the focus is on the sale of its 12,000m² property in Stikland, if a recent site inspection by a widely discredited property auctioneer is anything to go by. It appears the property could be split up and let out as small factory business units. Besides these issues, management of the group companies has been operating on a virtual turnstile basis. Managers at both the Roodekop sites in Johannesburg and in the Cape have been rotating at speed. A number of the managers in Cape Town have recently joined rival McNeil in Firgrove. Both DPI and Karbochem were major employers with estimated staff compliments, at their peaks, of about 400 people each.

JUST BRIEFLY

ANTI-STATIC specialist Fraser has launched an advanced product to clean and neutralise static in injection moulding workflows. The British company recently introduced its Roto-Clean 4900 unit, a static elimination system which blasts pulsating ionized air from single or multiple heads to clean and remove static that could attract further dust. Bruce Clothier, CEO at Fraser Antistatic Techniques, believes the unique device is the perfect complement to more traditional forms of cleaning and static control on the production line. According to Sarel Oosthuizen of Sareltech, the SA agent for Fraser, the system is well suited for injection moulding applications, especially for the motor industry. “Fraser has created a niche in cleaning and static elimination in injection moulding environments. This includes our traditional range of 4125 air guns, 5100 and 5500 airknives, and 4510 and 4400 nozzles. We have now developed Roto-Clean to complement the capabilities of the range. “Roto-Clean is incredibly versatile and can work as a standalone head on a robotic arm, or as an array over a production line conveyor. It has an unrivalled capability to clean complex shapes or bulky items and prevent further contamination, particularly where processes are heavily automated. “Its design is technically advanced, incredibly flexible,

It’s smoke and mirrors as Karbochem, DPI go down

DEC 2018 / Jan 2019 21

2018/11/20 12:03


News

Lovell Industries & Arengo Plastics

Food Safety Standard Recognition of one of SA’s longest standing blister pack manufacturers LOVELL Industries is one of the largest blister packaging manufacturers in South Africa and has, since its establishment in 1973, manufactured moulds and dies for various industries. In the 1980s the focus of mould making naturally moved into the blister packaging sector and, since then, Lovell Industries’ business model has continued to evolve: the company now specialises solely in the production of top quality blisters, trays, inserts and various other packaging related items. Lovell Industries, based in Bronkhorstspruit east of Pretoria, also specialises in the production of top quality food packaging, clear plastic blister packaging, food skillets, clamshell packaging, clear boxes,

transportation and shrink-wrapping trays, box inserts, cooling tower media and various other thermoformed plastic related items. To add to its incredible success as a proudly South African manufacturing business, Lovell Industries was recently successfully assessed and accredited to comply with the Food Safety System Certification FSSC 22000 v4.1 standards. The certification scheme for food safety management systems consists of the following elements: ISO 22000:2005, ISO/ TS 22002-4:2013 and additional FSSC 22000 requirements (version 4.1). The certificate is applicable for the scope of manufacturing (thermoforming/ die-cutting) of rigid plastic (APET, RPET, PETG, HIPS, PP), blister packaging,

display trays, cake lids/bases, food skillets, food clamshells, food trays, airline inflight trays, food punnets, biscuit skillets, chocolate skillets, clam shell packaging, clear tubes, clear boxes, clear die-cutting for the food industry; food chain (sub) category I. Arengo Plastics is Lovell Industries’ sister company and supplies the extruded sheet which is used in thermoforming. Arengo has been manufacturing and supplying rigid extruded sheet to the thermoforming and printing signage industries since 2005. It was also recently assessed and accredited to comply with Food Safety System Certification FSSC 22000 v4.1 standards, applicable for the scope of manufacturing (extrusion)

More high-tech test systems installed at Roediger Agencies lab New test systems allow Stellenbosch lab to further improve services

Analytical chemist Elana Bergh, lab manager at Roediger Agencies, conducting a test to identify additives on the company’s new Agilent Triple Quadrupole LC/MS (liquid chromatography, mass spectrophotometer) system

ROEDIGER Agencies of Stellenbosch, which offers SA’s only dedicated testing laboratory service for the polymer, elastomer and composites sectors, has made further investments in lab equipment. The systems installed over the past two years expand the company’s services, give it the ability to conduct a variety of new tests and also give it additional back-up to cover in the event of any test equipment failure, meaning that it can virtually guarantee that it can conduct just about any test required by product or material manufacturers. Given the size of the local converting market, the purchase of versatile systems was very necessary for the Stellenbosch lab which services manufacturers across the country and further afield. Systems from Agilent Research Laboratories and Thermo-Fisher Scientific of the USA and Netzsch of Germany, all top global test equipment marques, have recently been installed. Among these, the new Triple Quadrupole LC/MS (liquid chromatography, mass spectrophotometer) system from Agilent is being used to identify additives. The system can literally identify even the most minute additive content in material or moulded product samples and provide clear statistical reports for compliance to food grade or any health or related standard required. The new Netzsch calorimeter for thermogravimetric

22 DEC 2018 / Jan 2019

NEWS ARENGO.indd 22

analysis is being used for tests of inorganic fillers in polymers, which is necessary due to increased use of calcium carbonate (CaCO2) by bag manufacturers. Another instrument from Netzsch, a Polyma DSC 214 system, is being used for characterisation of polymers. This was a necessary investment for the lab after the previous system ‘blew up’ during an Eskom power outage. UPS and power generators have also been installed. Such events are a common hazard for test labs due to the use of extreme temperatures (heat or cold) and current as well as the elevated simulation of UV or other conditions. Also new at the lab, the Smart iTX accessory from Thermo Fisher is a specialised crystal spectrometer crystal which uses spectral data to identify polymers, copolymers and additives in plastics, inspect incoming raw materials and analyze volatile liquids. About the only area where Roediger Agencies is not involved is that of elemental testing, to identify exact chemical elements, where very expensive electron microscopes are required. extreme heat is applied. In such cases the tests are contracted out and, fortuitously, handled just as expeditiously. Besides that, there has been a lot of interest lately in testing of cannabis products, particularly of cannabis oils, given the recently changed legislation. www.roedigeragencies.co.za

2018/11/20 12:02


accredited to FSSC Securing futures for local community – The Lovell group of companies, being rurally based, plays a vital role in the local community from which it operates. Receiving the FSSC 22000 v4.1 certification is a momentous achievement and testament to the hard work of over 250 employees from this rural area that are employed in the various facilities of the Lovell Group. This has had a visible impact on the well-being and general upliftment of the local community and securing futures for many more generations to come

and supplying of rigid extruded plastic sheet (APET, RPET, PETG, HIPS, PP) for thermoforming/printing/die-cutting into food packaging. More about FSSC 22000 The standard ensures consumer trust in the supply of safe food and drinks. www.lovell.co.za

The FSSC 22000 Food Safety System Certification provides a framework for effectively managing an organization’s food safety responsibilities. FSSC 22000 is fully recognized by the Global Food Safety Initiative (GFSI) and is based on existing ISO standards. It demonstrates that a company has a

www.water-treatment.co.za

robust food safety management system in place that meets the requirements of its customers and consumers. • For more information about Lovell Industries and the FSSC 22000 Food Safety Certification, contact Kyle Lovell (managing director), p. (013) 932 8000; Kyle@lovell.co.za

www.arengoplastics.co.za

www.protect-a-plan.co.za DEC 2018 / Jan 2019

23

Reg No 80/05518/07

HIPs – GPPs – ePs –

PolystyReNe: GPPs/ePs/HIPs

With 35 years’ experience in supplying engineering polymers to the industry, our logistics & technical backup FoR All APPlIcAtIoNs – ABs – sAN – AcRylIc – AcetAl provide the highest level– of service and–support. NyloN – PBt Pc – sBc – HDPe – llDPe – eVA – PP ABS – Polylac MABS – Polylac ASA – Kibilac SAN – Kibisan GPPS – Taitarex / Denka / Polyrex / Supreme Q-RESIN – Kibiton / Denka Ps – ABs – AcRylIc – Pc HIPS – GPPC / Supreme NyloN – PP – HDPe – lDPe EPS – Taitacell / King Pearl PMMA – Acryrex SMMA – Acrystex (VARIoUs VA coNteNts) PC – Wonderlite KIBItoN PC/ABS ALLOY – Wonderloy Johannesburg Jeremy Goosen (T) 011 626 1030 jeremy@rawmac.co.za

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NEWS ARENGO.indd 23

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Delene Williams,

2018/11/19 16:47


News Rehau-MBT merger – Jobst Wagner (second from right), future chairman of the board of directors of the as yet unnamed new merged company, with fellow board members Philipp Endres, Thomas Endres (both of MBT) and Dr Stefan Girschik, who is to be CEO of the new business

Rehau group acquires MB Barter & Trading Merged group will create new global player in polymer industry REHAU GmbH, the procurement arm of the Rehau Group, and the worldwide trading subsidiaries of MB Barter & Trading AG will combine their strengths into a new, yet to be named, Swiss based company with an annual turnover of $2.5-billion. 24 DEC 2018 / JAN 2019

Both companies are active in South Africa: Rehau, a leading systems and service provider for polymer-based solutions in construction, automotive and industry, has factories in Port Jackson (EC) and Ladysmith (KZN), and offices in Johannesburg, Cape Town, Durban, East London and Uitenhage, focusing on advanced windows, doors and automotive parts. MB Barter & Trading is the main shareholder of MBT “Joining forces South Africa, one of South allows the new company Africa’s top polymer raw material importers to respond more quickly and distributors, to changing market established by conditions, innovate Dick Coates in faster, become more 1996, with offices in Johannesburg, Cape efficient and Town and Durban. Dick create higher value Coates will retain his for customers.” shareholding in the new entity. The announcement on 13 September stated that the merger “opens up significant opportunities for growth, increases global presence and strengthens the relationship with suppliers and customers”. “Joining forces allows the new company to respond more quickly to changing market conditions, innovate faster, become more efficient and create higher value for not only the customers, but also for employees and stakeholders alike,” said Dr Stefan Girschik, deputy CEO at Rehau and future CEO of the newly established company. The transaction is expected to close in the fourth quarter of 2018, subject to customary closing conditions and approval of antitrust authorities. www.rehau.com

Classifieds Oct/Nov'18.indd 92

2018/09/19 10:31

www.mbbarter.ch


Mall of Africa unveils worldfirst solar system THE biggest shopping mall on the continent, Mall of Africa, is set to unveil the largest rooftop solar photovoltaic (PV) system in the southern hemisphere. Located in Midrand in Gauteng, the mall’s new system will be a first for the region, with the record-breaking project being said to be the world’s largest integrated rooftop PV/Diesel hybrid solution. Owned by partners Attacq Limited (80%) and Atterbury Property (20%), Mall

Mall of Africa is set to unveil a world first in integrated renewable energy systems, with the largest rooftop solar photovoltaic (PV) system of its kind in the southern hemisphere and tenth worldwide

of Africa offers over 130 000m² of retail space. The 4755kWp project which covers the mall’s roof space – an estimated 45 000 m² – will generate energy that will power the mall’s daily operations. “This project will see the mall produce sufficient power to support its day to day electricity requirements while also decreasing its overall carbon footprint – another significant proof point in our sustainability journey,” said Head of Retail

Asset Management at Attacq, Michael Clampett. Producing 7 800 MWh annually, the project will contribute to the integration of renewable energy in the country’s energy mix, support local economic growth and have positive environmental impacts. Having played an integral role in the installation of the solar PV system, Atterbury Property said that this system is the first of many that it plans to install in their buildings. DECEMBER 2018 / JANUARY 2019 25

MBT South Africa Distributors of Plastic Raw Materials Paul Gripper Carlotta Stafford Helga Ferreira Steven Coates Tiago dos Ramos Head office Cape Town

Trading Manager (Cape Regional Sales) (Zambia, Malawi and Lesotho Sales) (Gauteng, Zim, Moz, & Angola Sales ) (Gauteng, Botswana, Namibia & Swaziland Sales ) (KZN & Free State Sales) Johannesburg Office

www.mbtsa.co.za

082 456 6659 082 600 7403 072 573 4221 063 699 5105 082 775 5344 +27 (11) 455 2889 +27 (21) 556 7787


News

Right: Among the first moulds to be supplied to a HellermannTyton group company, in this case in Poland, was this multi-cavity tool for the production of a complex-shaped automotive wheel arch drainage component

Far right: The management of the new engineering team at HellermannTyton in Johannesburg includes Chantelle Phillips, Peter Phillips and Jonathan Phillips

HellermannTyton SA Engineering team at Joburg Co. surprises all and sundry IT’S NOT often that you hear of tools being supplied from South Africa to Germany, if ever for that matter, but remarkably that is the case at HellermannTyton in Johannesburg. The engineering team at the company’s Linbro Business Park plant is, surprisingly, supplying moulds back to the global group’s German parent company for use there and by other Hellermann manufacturing companies internationally. Headquartered in Germany, the HellermannTyton group is involved mainly in the production of automotive & electrical cable management components. In South Africa, however, the company is involved almost solely in the manufacture of cable ties and related cable management components; the SA group company is the leader in this very competitive area in the southern Africa region. Up until recently all the SA company’s moulds were acquired from other group companies internationally, and a large portion of the group’s moulds were being manufactured in the groups manufacturing plants in Europe and China. It was decided to expand the Johannesburg toolroom’s maintenance and manufacturing abilities, and potentially do more new and automotive component manufacturing, and the opportunity to do so was presented when HellermannTyton SA purchased PVS Engineering from Pretoria in 2015, specialising in Engineering, Design and manufacturing of moulds and

automotive components. The directors of HellermannTyton SA identified PVS Engineering a suitably skilled toolroom for merging, with the aim of expanding auto component production by the company in SA, in sync with other HellermannTyton group manufacturing units globally. Fortuitously, the merge of PVS by HellermannTyton SA went through smoothly and the company’s plant and machinery was moved to Linbro. At that stage all the SA company’s moulds were still being supplied from other group companies and the initial intention was for the engineering team to perform mainly repairs to moulds on site, but it appears the team led by Peter & Jonathan Phillips did not stick to the script and put their skills to work in building moulds for cable tie production and local OEM automotive production supply. which – due to the thin and long flow paths required – are seen as challenging, not least because cable tie production by definition requires multi-cavity operation, complicating the undertaking. Thereafter, the toolroom managers at HellermannTyton GmbH in Tornesch, Germany, gave the local team the go ahead to build cable tie moulds. The construction of automotive moulds tends to be significantly more complicated, as many of the plastic parts in use have

“The SA group company is the leader in this very competitive area in the southern Africa region.”

26 DEC 2018 / JAN 2019

NGR


exports tools to Germany complex geometries. After completion of the first auto mould design and construction job, carried out by father-and-son team Peter and Jonathan Phillips and their toolmakers and appies, was successfully trialled, the team got the green light to proceed. Such has been the expertise and momentum built up over the past three years that the local team has been building moulds for use in Germany and elsewhere in Europe, and the demand is not only based on the fact that the exchange rate favours the euro-zone group customers. The team have received some accolades from the parent company, with the comment “We’ve never seen something like this

come out of Africa” being especially memorable. The success so far is to a great extent the result of good teamwork and leadership “We have a close knit team who should take full credit for the growth opportunity that has been created after Germany realized the SA engineering team’s tremendous capabilities,” said Chantelle Phillips, Technical projects manager at HellermannTyton in Johannesburg. HTSA Engineering is now also part of the global innovation group with annual global meeting sharing information, technologies and ideas in improving standards, processes and technologies in the group.

www.hellermanntyton.co.za

DECEMBER 2018 / JANUARY 2019 27

Tel: +27 11 803 0333 mervynm@safrique.com

NGR ad '018 12-NEW.indd 24

2018/11/17 09:41


News

New from Progetto:

automated carton packer ‘SA solution’ for 24/7 case packing with only minimal attendance PROGETTO, the in-line automation systems provider, has developed its own automated carton packer solution. At first glance, the Progetto design of this important packaging utensil appears straightforward … but on closer examination the interested party will find that there are a number of features that required highly specific and accurate positioning of shifters and moving arms and coordination of the various parts. If that’s not enough of a challenge, bear in mind that the line also needs to, unattended, move containers and cartons into the packing zone, complete the tray packing application and then smoothly move the packed and sealed cartons out of the system, which is no mean feat. The main aims with automated packers include the need for a small footprint, in order for the unit to be positioned in-line and as close as possible to the moulding machine(s), highly predictable operation capable of running 24/7 with minimal attendance and the need to be relatively easy to programme and control. And then to come in at a price which doesn’t cause health issues for the buyer.

Rocky Stone and the Progetto team, based in Killarney Gardens, Cape Town, are involved in several areas besides plastics, but their systems are well suited to plastics as the moulded goods tend to be light and hence relatively easy to move by conveyor. That attractive aspect falls away, however, once the containers are filled, which is another area where Progetto has good expertise. Stone himself has been involved in automation development for close to two decades and Progetto (established 2006) has achieved some breakthrough development virtually every year. Besides it’s conveyor systems, for which it is well-known, Progetto already manufactures leak testers and trimmers, labelling and filling lines and other specialised systems for more difficult requirements such as metal detection and wrappers.

28 DEC 2018 / JAN 2019

Vacuum hopper loader

For conveying of free-flowing plastic or powder materials Stainless steel hopper with separate control, separated from the machine with an extra long cable. Suitable to locations difficult to access or for applications requiring a stainless steel hopper. Con-Evator is available in: 4, 8, 16, 26, 50, 75, 100, 150 and 200 Litre FdB CONSULTING Tel: +27 (0) 82-651 3315 frank@fdbconsulting.co.za www.labotek.com

One of the first versions of the new carton packer from Progetto includes a vertical unscrambler, for sorting and aligning caps, but this unit can be completely done away with when containers or other moulded goods need to be packed into cartons – in which case the moulded items will enter the system by horizontal conveyor

www.progetto.co.za


Classifieds Apr/May'18.indd 92

2018/04/16 10:36


SAPY Advert 2018.indd 86

2018/05/21 11:52


News

Pratley ready for

FrogzEggz mania

Hand-mouldable plastic aimed at diverse range of markets THE latest inspiring product to sweep South Africa is a handmouldable plastic material from Pratley. Called FrogzEggz®, it’s sure to have the likes of DIYers, arts-and-crafters, cosplay fanatics, teachers and schoolchildren firing their imaginations to come up with clever and inventive uses, as well as more off-the-wall ideas, for the product. FrogzEggz hand-mouldable plastic is aimed at a diverse range of markets: from arts-and-crafts enthusiasts seeking inspiration, to DIYers in search of a new material for car repairs and around-thehome projects, to teachers helping learners unleash their creative potential, as well as cosplay devotees wanting to enhance their designs. The name is derived from the opaque, granular plastic material that, after being heated in hot water, clumps together to form a transparent, pliable mass that resembles frogs’ eggs. It can then be shaped into a range of objects, from jewellery to glow-in-the-dark figurines, and even costume accessories. Just a few examples of DIY use include; screwdriver handles to replacement plastic parts where the originals have broken, fishing lures, grip enhancements, flashlight or cellphone holders, camping and sporting accessories, hair clips, light switch covers, rings,

The opaque, granular plastic material clumps together to form a transparent, pliable mass that resembles frogs’ eggs and can be shaped into a range of objects

bracelets and buckles. An added advantage of FrogzEggz is that it can be reused over and over by simply re-submerging it in hot water until it softens again, whereupon it can then be remoulded. DEC 2018 / JAN 2019 31


News

Global association directors face similar problems to SA

Delegates impressed with Plastics/SA’s systems

Altech UEC machines sold off

JUST BRIEFLY

ALL the injection moulding machines at Altech UEC, the Durban-based moulding company, have been sold off, mainly to a KZN convertor. The UEC moulding business itself has apparently been sold to a Far Eastern group which is importing all the television, set top box and related components, which is to say that only assembly and no moulding will be conducted at the Mt Edgecombe company. At one time (2014) Altech UEC was busy with one of the biggest product rollouts ever seen in the local plastics industry: the injection moulding and assembly of over half a million ‘set-top boxes’ a month in a project to supply TV subscribers across Africa.

Vinmar celebrates 40yrs

FROM humble beginnings in a Queens, New York apartment in 1978, Vinmar International has steadily grown into a major player in the global petrochemicals industry. Today, the Houston headquarters and offices in 34 major markets work together to serve over 100 countries around the world supplying a wide range of polymers. Vinmar is present in South Africa through Chemplast Distributors, run by Graeme Smith, in Durban from where it supplies nationally and across southern Africa. 32 DEC 2018 / JAN 2019

PLASTICS|SA hosted the Council of International Plastics Association Directors’ 2018 meeting in midNovember, which was attended by fellow trade association directors from around the world … and the main observation to be drawn was that most of the other countries have similar problems to what we have in South Africa. Besides that, the global directors appeared to be highly impressed by the structure and reach of the South African body, which was a definite shot in the arm for the Plastics/SA team. The main problems faced by the other CIPAD members at present are the result of environmental pressure from lobby groups which is having an impact on the industry in terms of the phasing out of ‘one-way’ packaging containers and particularly the prevelance of plastics ocean pollution, which consumer groups have mounted sustained attacks against. Other global groups are involved with CIPAD too, including the World Plastics Council and Global Plastics Alliance,

each apparently with its specific role, but the meeting was all about trying to curb the environmental pressure and trying to develop sustainable solution. Philip Law of the British Plastics Federation focussed on the topic in his ‘Plastics’ Place in a Sustainable Society’ address. Ironically, far less plastics recycling takes place proportionately in Britain than in South Africa. Until quite recently Britain was exporting much of its plastics scrap to China, but that outlet has recently been shut off. Participants, including the international visitors and local delegates (including convertors and material suppliers), undertook a wide-ranging tour on the Friday, including a visit to a river ‘litter boom’ installation, the Packa-Ching buyback centre in Langa, the Kraaifontein Integrated Waste Management Facility and Tuffy Brands’ refuse bag manufacturing plant in Bellville. The locals integrated well with the global guests and as a window to the state of our industry, congrats are due to all the players.

Sponsors – The global gathering in Cape Town was co-sponsored by Sasol Base Chemicals and Dow Southern Africa, represented by Max Vreugde and Cecilia van Rooi respectively – thanks to their companies for their generous support of the international event

Global counterparts – PlasticsSA director Anton Hanekom with two of his associates, Dr Jürgen Brüder of IK (Industrievereinigung Kunststoffverpackungen) of Germany and Philip Law of the British Plastics Federation

The main problems faced by the other CIPAD members are the result of environmental pressure from lobby groups.


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News

The future of

34 DEC 2018 / Jan 2019

Expo Centre in Nasrec, Johannesburg, 12-15 March AFRICA’S ultimate packaging, food processing, plastics, printing and labelling exhibition returns next year and will be taking place at the Expo Centre in Nasrec, Johannesburg, from 12-15 March 2019. A renowned local and international brand, the industries it represents have come to count on Propak Africa for its showcase of the latest innovations and technologies, sustainable packaging initiatives, and the most cutting-edge machinery and equipment.

Leading players in the packaging and related industries are looking forward to engaging with visitors and sharing information on their range of products, services and solutions. Many new products and services will be launched at the show, with machinery on display for the first time in South Africa. “Propak Africa is the place to be to see the future of all things packaging,” says Sven Smit, Event Director for Propak Africa. “Effective, striking and sustainable

packaging has never been more important and all the latest innovations will be on show across Propak Africa and co-located shows FoodPro, Pro-Plas Expo, Print Expo and Pro-Label Africa. Our aim is to showcase the latest developments across the full industry life-cycle – from the raw materials, to packaging, storage and transport, and finally, recycling and waste management.” “In addition to the interactive product displays, live demonstrations, advice provided by the technical experts on the stands and several exciting new initiatives will benefit visitors to Propak Africa 2019,” says Smit. “For the first time ever there will be free-to-attend seminars taking place daily at the show. These will be presented by expert speakers and the content will be aligned to the show’s ‘four days, four themes’ topics. The themed days are also part of our new initiatives,” he says. The new Seminar Theatre will take place in Hall 7 and visitors will be able to attend as many of the seminars as they choose, free of charge. Packaging for the

Extrusion lines for plastic recycling suitable for materials with high level of moisture and print.

NEWS PROPAK.indd 34

2018/11/19 16:35

Roed


Conferences alongside Propak Africa More knowledge and industry insights will be available to delegates as they listen to top industry speakers who will be presenting at several conferences taking place alongside Propak Africa. These will include an IPSA Think Tank, Printing SA and South African Institute of Printing (SAIP) Conference, SAPRO South Africa Plastics Recycling Organisation (SAPRO) Indaba, and a Packaging Innovation & Sustainability Conference.

35

Local brand with international flavour Propak Africa has built its reputation as a strong and reputable brand over the past twenty years. A triennial show, it has consistently attracted over 12,000 visitors

since 2007 with a slight dip in numbers in 2016 due to the torrential rains that were experienced during the show. Although the majority of the 11,670 visitors in 2016 were local visitors, a strong contingent of international visitors included representation from over 20 African countries. There were 620 exhibitors at the show in 2016 including internationals with countries represented that included the United Kingdom, India, Taiwan, China, Belgium, Austria, Portugal, France, Turkey, Greece and the UAE as well as an Italian pavilion. By the close of the 2016 show, over 35% of the show had already been re-booked by exhibitors for Propak Africa 2019. Considering they were booking three years in advance, this demonstrates the immense support for the show and an acknowledgement of its success and value. Over 600 exhibitors are expected in 2019. • For further information, contact Keraysha Pillay, marketing manager/ Propak Africa, p. +27 10 003 3057 kerayshap@specialised.com

DEC 2018 / Jan 2019

TESTIN

accredited courses alongside the exhibitions. There will also be a display of the Institute of Packaging SA’s Student Goldpack Award-winning products – a window to future innovation. A Propak Africa App has also been developed to keep visitors updated prior to and during the show.”

www.propakafrica.co.za

Future, Packaging 4.0, Top Consumer Trends, Africa Insights, SA Packaging Market Overview, Barriers to Recycling Plastics Waste, The New Dimension in Digital Printing and Packaging Design vs Product Information are just some of the topics that will be available to visitors. Also new at next year’s show will be the themed days. Day one will focus on new products; day two will centre on sustainability; day three will put the spotlight on skills development; and day four will be a ‘Local is Lekker’ day, where the South African Propak Africa brand and local manufacturers and products will be celebrated. “Other new initiatives will include a Wi-Fi Café in Halls 5 and 7 which will provide free Wi-Fi connectivity as well as charging stations to allow local and international visitors the opportunity to charge their devices,” says Smit. “We are also in the process of finalising a skills development area and conversations are taking place around the possibility of having CPD

News

all things packaging at Propak Africa 2019

G for food contact compliance

Our ThermoScientific ‘Trace’ 1310 chromatograph allows us to test all packaging materials for food grade compatibility. Forward samples of packaging materials – including films, containers, closures, pouches and any other plastic or composite material that is used for the packaging of food substances or beverages – to us and we conduct full testing to European Regulation No 10/2011 amended as No 1282/2011.

Roediger Agencies cc Analytical Laboratory ● Identification of unknowns ● Additive analysis ● Chemical properties ● Physical properties ● Weathering services

Contact: Dr Andy Roediger t. 021 887 0010 f. 021 886 4731 e. Andy@roedigeragencies.co.za

www.roedigeragencies.co.za

NEWS PROPAK.indd 35 06.indd 1 Roediger Agencies ad '014

2018/11/19 16:36 2014/05/19 12:22 PM


Middle East

Iraq plans to increase production at its giant Majnoon oilfield to 450,000 barrels per day (bpd) in three years, from 240,000 bpd now

The Hammar Mushrif new Degassing Station Facilities site inside the Zubair oil and gasfield, north of the southern Iraqi province of Basra. (Haidar Mohammed Ali/AFP)

Iraq finally starting its overdue economic recovery

Many challenges, but could develop large, well- established petrochemical indus BY NIALL MARSHALL

SAUDI Arabia, with its giant oil and gas reserves, has a large and wellestablished oil and petrochemical industry. This industry relies on an extensive infrastructure for transporting oil and associated gas from thousands of oil wells in the scattered on-shore and off-shore oil fields via purification and separation plants to refineries, crackers and various chemical plants. Some of the crude oil is refined, or separated into petrol, diesel, kerosene and jet fuel in Saudi Arabia while the balance is sold as crude oil to refineries world-wide. The associated gas, gas that is found ‘associated’ with oil, is captured at the well-heads and transported through vast networks of pipelines to ‘crackers’, billiondollar plants that convert the associated gas into ethylene and propylene which are then used to make polymers. The cost advantage that Saudi Arabia (and other Middle Eastern countries) have for producing polyethylene is thanks to the associated gas: associated gas gives the lowest cost ethylene. If the gas isn’t captured at the oil well and transported to where it can be sold or used it has to be flared. Slightly more expensive than associated gas is shale gas. The availability of low-cost shale gas in the USA has led to a renaissance in the American polymer industry. Outside of the Middle East and USA most ethylene is produced via a much more expensive process from naphtha. Based on its oil and gas riches Saudi Arabia produces almost 100 million tons a year of petrochemicals, including almost 20 million tons per annum of polymers! While the actual volume of polymers produced by Saudi Arabia might be unexpected, the fact that the largest producer of oil in the Middle East,

Saudi Arabia, is the largest producer of polymers in the region is not surprising. What is surprising is that the second largest producer of oil in the region, the second largest producer of oil in OPEC and the country with the fifth largest reserves of oil in the world produces less than 100 000 tons of polymer per year. Or maybe, if you know that Iraq is the second largest producer of oil in the Middle East, its not surprising at all. There is only one polymer producer in Iraq in Basra in the oil-rich south east of the country close to the border with Iran. The site, which was built in 1977, includes HDPE, LDPE and PVC plants, although only the two polyethylene plants seem to be running now, PVC hasn’t been produced since 2000. There is a small polymer converting industry in Iraq, mostly situated near Baghdad. Considering that Iraq has suffered through more than 40 years of sanctions, war, unrest and insecurity, it is remarkable that the industry exists and processes around 100 000 tons of polymer per year, mostly packaging but also for the construction industry. Any economic recovery in Iraq will benefit companies supplying the construction industry as well as the agrifilm and packaging producers supporting the historically important agriculture sector which has been negatively affected by the ongoing conflicts. With a new government in place and the large swathe of territory seized by the so-called Islamic State in 2014 recaptured, there is increased optimism that Iraq is finally going to start its overdue economic recovery. Over the last few years it has managed to attract foreign investors, mostly oil companies, and this has resulted in increased oil production. Iraq is producing around 5 million barrels per day (for context,

try

South Africa consumes about 580 000 barrels per day) and plans to increase this to 8,5 million barrels per day over the next five years. Most of this oil is exported unrefined (Iraq imports petrol and diesel for its own use) and so, in addition to increased utilization of its oilfields, it is building three new refineries (with a combined capacity of 600 000 barrels per day) as well as rehabilitating a number of small existing refineries. There are also projects to capture the associated gas from the oil fields, presently most of this gas – enough ethane to produce 1 millions tons of polyethylene – is flared every year. It is estimated that more than $200 billion in revenue has been lost over the decade by burning off the associated gas – and as oil production is increased the volumes of associated gas also increase. The first major gas-capture projects are underway and it is planned to stop all flaring by 2021. Associated gas will feed planned petrochemical plants near Baghdad, in Al-Faw and in Basra. In 2015 Shell announced it will invest in the $11 billion Nebras complex near Basra which will include a cracker and a 1,8 million ton pa petrochemical plant including polymer plants. Earlier this year it was announced that Sabic is in talks to join the project. Total has also announced that it is studying a project in Basra which could include polymer production. And the existing polymer plant has mentioned a plan for a 400 000 tpa polypropylene plant. Iraq is a country with a lot of potential for polymer production – today it is in the same position that Saudi Arabia was in the 1980’s when it first started producing polyethylene with giant gas and oil reserves. Although Iraq faces many challenges, one day it too could have a large and well-established petrochemical industry.

36 DEC 2018 / Jan 2019

Middle East feature.indd 36

2018/11/20 12:24


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ENVIRO

South Africans unite Spending one day to help clean a beach will make a difference in keeping South Africa’s coastline clean

Even the children were excited and happy to help clean up the beach

Although it was slightly rainy in Cape Town, the volunteers were still very motivated to keep up their fantastic work and respond to the call to help create a waste-free world

Volunteers get dirty to help free

38 DEC 2018 / JAN 2019

More than 130 assist in iconic landmark’s largest clean-up to date ONE of South Africa’s most famous landmarks, Robben Island, was freed from some of its waste burden as more than 130 volunteers, guided by the national PET Recycling Company (PETCO) and Plastics/SA, embarked on the island’s biggest ever waste collection drive in September. The tourist attraction and World Heritage Site, which draws over 300 000 visitors annually, is plagued by visitor litter as well as waste from passing ships and landbased sources – the latter washing into Cape Town’s stormwater drains and rivers, and ultimately Table Bay. The event, in honour of World CleanUp Day on 15 September, came amid continued warnings from researchers that that litter is growing faster than the

ENVIRONMENT.indd 38

human population. In Cape Town, the amount of litter washing up on the city’s beaches increased by 300% between 1994 and 2012 alone. According to University of Cape Town researcher Professor Peter Ryan, an expert on beach litter along SA’s coastline, roughly 10 times more litter washes ashore at Milnerton than at Koeberg, indicating the importance of local, mainly land-based sources of litter within the bay. “We don’t have much evidence of direct impacts [of litter] on the island’s wildlife. There are records of birds being entangled in litter [on Robben Island], including an endangered Bank Cormorant chick,” said Ryan. PETCO stakeholder relations manager Janine Basson said since the majority of

ocean waste was derived from landbased sources, stopping waste at source was ultimately the most effective way to deal with marine pollution. “Keeping recyclables, like PET plastic bottles, in the economy – instead of ending up in landfills – is key,” said Basson. Since PETCO’s inception in 2004, Basson said PET producers had contributed voluntary recycling fees in excess of R371-million which had enabled the collection of 14 billion discarded PET Volunteers Brian Allott and his 5 year old son Kallon Allott

2018/11/19 16:51


along two oceans, although many more unregistered, community driven spontaneous events took place throughout the week and on the day. Highlights of the 2018 event in South Africa include: • Hosting three of the largest off-shore island clean-ups that took place on Robben Island, Dassen Island & Bird Island • Growing clean-ups on the Wild Coast from seven in 2017 to 42 this year. • Initiating beach clean-ups in ecologically sensitive areas and areas with no area cleansing services The biggest litter bugs To get a detailed snapshot of the biggest pollutants on the country’s beaches, the Plastics|SA team will again be spending time analysing the data sheets that were filled in by volunteers at the audited clean-ups. Despite extensive education and awareness campaigns that have taken place in South Africa over the past few years, Kieser remarked that the volunteers were all shocked to see the amount of litter strewn on beaches and between rocks. The most prevalent items collected each year are earbud and sucker sticks, straws, sweet wrappers and cigarette butts.

Robben Island from waste burden

ENVIRONMENT.indd 39

Melissa Mcbain of Nourish’d Café

the entire circumference, except for the penguin breeding area. The Robben Island clean-up was organised and managed by The Beach CoOp, using the “Dirty Dozen” methodology developed by Prof Ryan to record and track the sources of marine waste collected. Co-op director Aaniyah Omardien said employing this methodology at all clean-ups helped to better understand Cape Town’s waste streams and improve the city’s waste management strategy.

39

Kara Levy of PETCO

Island for the past 20 years. “Some of our most successful clean-ups have been on Robben Island, including one in which we stopped the incineration of waste, and managed the closure of two dump sites. We also started the Working for the Coast project on this island, with two weeks of solid clean-ups,” said Kieser. He said the 15 September clean-up represented the biggest stretch of the island’s coastline they had yet been permitted to target, which was essentially

DEC 2018 / JAN 2019

plastic bottles for recycling, thereby reducing landfills by 3 777 639m3 and carbon emissions by 913 107 tons. PET recycling had created R5.4-billion in economic value to date, and 64,000 income-generating opportunities in 2017 alone, she said. Plastics|SA sustainability manager John Kieser said the plastics industry body – which includes polymer producers, converters and recyclers – had been active in cleaning up Robben

www.worldcleanupday.org.za

Effective waste management to follow up civic action “The purity of our oceans is a crucial issue for our country. However, it is important to remember that clean-ups do not offer a long-term solution and are not meant to replace regular waste management. With events such as this past weekend’s World Clean-up Day, the aim is to draw attention to littering, trash blindness and general mismanagement of waste. Civic action must be followed up by effective waste management reforms. Improved waste collection and management must be established everywhere. We also need to look at what we are throwing away, because nothing is waste until it’s wasted. Plastics and other packaging material should not end up in landfills and definitely not in our oceans, because they are valuable resources should be recycled,” Kieser concluded.

www.plasticsinfo.co.za

THOUSANDS of South Africans rolled up their sleeves, put on their rubber gloves and took to the beaches in September as part of the first World Clean-up Day – the largest peacetime civic action in human history. Stretching across 24 different time zones, involving 144 countries and more than 13 million volunteers worldwide, World Clean-up Day started in Fiji and moved around the globe with the time zones, ending in American Samoa 24 hours later. In South Africa, 26 000 registered volunteers and many more unregistered citizens arrived at beaches between 09:00 and 12:00 to do their bit to pick up and remove litter from our marine environment. Plastics|SA and sponsors partnered with Let’s Do It! Africa and Ocean Conservancy by coordinating South Africa’s involvement in this year’s clean-up, and provided resources in the form of 300 000 specially printed yellow refuse bags, latex gloves and ground support to make this one of the biggest events ever to take place in South Africa as part of the annual Clean-up and Recycle SA Week. According to John Kieser, Sustainability Manager at Plastics|SA and coordinator of the beach clean-ups that took place in KwaZulu Natal, Southern, Eastern and Northern Cape, the annual event has grown tremendously since the first time South Africa took part in the International Coastal Clean-up Day 22 years ago. “The public awareness about the damage litter causes to the marine environment and a willingness to do something about it, has reached an all-time high. Regardless of their age, gender, race or economic position, South Africans realise that even the smallest effort makes a big difference in the end. Saturday saw one of the biggest turn-outs of volunteers we had ever seen as people from all walks of life put their differences aside and worked shoulder to shoulder for a great cause,” Kieser said, thanking all the volunteers and the various sponsors who participated and helped to make the event a huge success. More than 110 official clean-up events took place around South Africa’s coastline that stretches for more than 2 500km

www.cleanupandrecycle.co.za

Thousands rolled up their sleeves for world clean-up day 2018

ENVIRO

for a clean environment

Volunteer Nadeema Peterson

2018/11/19 16:51


ENVIRO

Ocean Cleanup sets sail to Great Pacific Garbage Patch Free-floating system to collect marine debris A TUGBOAT departed San Francisco Bay on 8 September bound for the Great Pacific Garbage Patch with a marine litter collection system in tow, designed to rid the seas of plastic. According to PlasticNews.com, the tug was deployed by the Rotterdam, Netherlands-based non-profit group Ocean Cleanup. The 610-metre-long system consists of a floating plastic boom with a tapered plastic screen extending 3m underwater. The plan is to capture plastic debris at or near the surface for eventual recycling. The launch was the culmination of five years of ocean plastic research, prototyping and fundraising. The project attracted about $35 million in donations and sponsors like PayPal co-founder Peter Thiel. The system was designed so that the buoyant and flexible HDPE pipe stays on top of the Pacific Ocean to keep garbage from flowing over it, while the drag on the skirt, which is tapered, forms a U-shape that captures plastic floating at or near the surface. Most marine life is expected to swim underneath the system, which was dubbed Wilson in a nod to the personified volleyball friend of actor Tom Hank’s stranded character in the 2000 movie ‘Castaway’. The pilot test for Wilson was conducted with 120 metres of Agru XXL pipe and 72 metres of skirt or screen that is 3 metres deep at the centre. The system was assembled with clamping brackets in California and then pulled by boat through San Francisco Bay for 1 200 nautical miles to the trash vortex in the Pacific Ocean, between California and Hawaii. The largest of the five zones where plastics accumulate, the North Pacific garbage patch if filled with fishing nets

The 610-metre-long system consists of a floating plastic boom with a tapered plastic screen extending 3 metres underwater. The plan is to capture plastic debris at or near the surface for eventual recycling

(46%), with 20% coming from the 2011 tsunami in Japan. Much of the plastic is rigid PE and PP. Produced in Charleston by Agru America Inc, XXL pipe is available with outer diameters up to 2 500mm and lengths up to 600 metres for on- and offshore applications. The pipe can be extruded into Charleston Harbour and when capped at the ends is buoyant for towing by tugboat to customers around the world for mining jobs and coastal projects like cooling water intakes for power plants and seawater desalination plants. The Ocean Cleanup envisions a fleet of 60 plastic-culling floaters that are 600 metres long each and equipped with solar power lights, cameras, sensors, anti-collision beacons and satellite antennas to communicate their locations and gather performance data, including an alert that the U-shaped centre is full. In optimal conditions, every week, 1 metric ton of plastic debris will accumulate in front of the system. Garbage-hauling vessels will arrive periodically to pick up the plastic

The pilot test for ‘Wilson’ was conducted with 120 metres of Agru XXL pipe and 72 metres of skirt or screen that is 3 metres deep at the centre

and take it to land for recycling into products like sunglasses, backpacks, headphones and watches. The Ocean Cleanup says this full-scale fleet could pick up 50% of the Pacific garbage patch every five years. The plastic returned to shore for recycling will be sold to businessto-consumer companies and that money will go toward cleaning up the other gyres in the South Pacific, North and South Atlantic Ocean, and Indian Ocean. The system also may be equipped with pingers to deter marine mammals and green flashing lights to deter sea turtles. When the area is cleared of marine life, a net will be towed by the main vessel and closed slowly. The catch will be transferred on board to a brailer with fine mesh to collect macro- and microplastics. Any living small fish and other organisms will be manually separated, if possible, documented and released back into the ocean. The extracted plastic will be deposited in open-top containers with drainage holes and commercial-grade filters to retain microplastics. The plastic will then be shipped to a drop-off point in the San Francisco Bay area, moved to labelled containers and taken to a recycling site, where it will be pre-treated to remove biomass and inorganic fractions. Nonplastic debris and plastics not suited for mechanical recycling will be subject to thermal recycling.

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ENVIRO

Plastic-eating mushrooms … Fungi optimal capable of removing pollutants from soil and wastewater

By CHANDER MOHAN, krishijagran.com

ACCORDING to a recent study conducted by London based Royal Botanic Gardens in Kew claims that fungi are capable of expediting the breakdown of plastics. The aspergillus tubingensis fungus was featured in the State of the World’s Fungi 2018 report, which also documented that fungi are optimal in producing sustainable building materials and are capable of removing pollutants from soil and wastewater. Whereas plastic generally takes years to degrade, the mushroom, first discovered growing in a Pakistani dump in 2017, could make it possible to break down the pollutants in weeks. The 2018 report is the first release of its kind, marking its debut with the monumental discovery that mushrooms could provide a solution to the growing plastic waste crisis. Because its properties catalyze the deterioration of plastic molecules, the report announced that aspergillus tubingensis “has potential to be developed into one of the tools desperately needed to address the growing

Whereas plastic generally takes years to degrade, the mushroom, first discovered growing in a Pakistani dump in 2017, could make it possible to break down the pollutants in weeks

environmental problem of plastic waste.” According to the scientists, the mushroom has the ability to grow directly on the surface of plastics, where it breaks down the chemical bonds between the plastic molecules. Armed with a unique enzyme that is secreted by the sprout, aspergillus tubingensis is one of the most interesting fungi featured in the team’s research paper. It is also confirmed that white rot varieties of fungus-like pleurotus stratus and versicolor have a beneficial effect on soil and wastewater, removing pesticides, dyes and explosive remnants. The trichoderma species has been identified as a stimulant for producing biofuels through its conversion of agricultural waste into ethanol sugars. Fungal mycelium is also notable, especially for designers and architects interested in finding sustainable replacements for polystyrene foam, leather and several building materials.

Students in India are fighting back by sending waste wrappers back to manufacturers A dramatic act of protest reminds companies of their responsibility THERE comes a point when there is not much more we can do from our individual perspective if big companies don’t take responsibility for the full lifecycle of their packaging.

Students of Subbiah Vidyalayam girls’ higher secondary school in Thoothukudi, India, have taken on an initiative to tackle this issue. To date, they have collected 20,244 wrappers from the packaged foods they consumed in exactly two weeks, with just over 10,000 attributed to food manufacturer Britannia and another 3,412 to wafer-maker Nabati. They sent the wrappers back to the manufacturers along with a note that read, ‘we are happy The more pressure placed on companies to handle their own waste, the sooner we’ll see change

with the taste and quality of your products, but unhappy with the plastic

packaging. We want to ensure a safe environment for our future generations and minimise our plastic footprint. We have decided to collect used plastic wrappers of your products and send them to you for safe disposal. Please help us savour your products without guilt, by introducing eco-friendly packaging.’ It has been reported that the experiment was a great success, and although the companies haven’t responded, the more pressure that is placed on companies to handle their own waste, as opposed to consumers, the sooner we’ll see deposit schemes and bulk stores that allow reusable containers appearing in our cities. www.treehugger.com Getting kids involved will inspire younger generations with a desire for change and they’ll forge ahead with a determination 42 DEC 2018 / JAN 2019

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Associations

IOM students look at key topics Research suggests

44 DEC 2018 / JAN 2019

THE Institute of Materials’ annual student evening was held in late September at the St Georges Club in Port Elizabeth. Fewer presentations than usual were presented, but the two PhD students involved on the night made up for lack of numbers with sheer interest. The two speakers, both doing their doctorate studies at the Nelson Mandela University, gave comprehensive summaries of their research work, with Keith Nare covering the topic ‘From Crude Oil to Application: A Low Temperature and Aging Nexus Approach to Material Memory’ and Darrel Naidu looking at ‘Development of Bio-Based Xylan Composites for Food Packaging Applications’. Keith Nare is working on a project with LABCO, a SANRAL materials training laboratory, about rheo-fingerprinting of bitumen obtained from different refineries in South Africa. This rheological data can be used as a predictive tool for the behaviour of bitumen in the construction of roads. Darrel Naidu’s presentation seeks to provide an alternative packaging material produced from biodegradable polysaccharides. The choice of material was inspired by the fact that approximately 75 million tons of agricultural waste in South Africa is either burnt (sometimes to create electricity) or dumped. These biomass residues are classed as lingo-cellulosic biomass and comprise mostly of cellulose, xylan and lignin. Through various pre-treatment methods, it is possible to selectively extract these lignocellulosic components for various applications such as packaging. What’s happening in REDISA’s wake? The final speaker on the night was Dr Percy Hlangothi, one of the Polymer Science lecturers at NMMU. Dr Hlangothi mentioned that a lot of research projects in the Centre for Rubber Science & Technology were still about the waste tyre recycling and beneficiation, a legacy of their partnership with REDISA. Unfortunately, the liquidation of REDISA strained costs of running these projects and potential funding is being sourced to continue research in this field. Some of the projects that are underway include: • Exploring chemolysis of waste tyres as an alternative to pyrolysis; • Valourisation of waste tyre derived carbon char by blending with biomass (wood and algae) to produce fuel pellets for potential use in households; • Refinement of pyrolysis oil through various methods; • Devulcanisation of rubber vulcanizates using novel organic compounds and methods; • The use of waste tyre crumb rubber in secondary applications such as modification of bitumen, development of plastic composites and rubber compounds. Students do the talking – Darrel Naidu (left) and Keith Nare (second from right) with lecturer Dr Mohau Phiri and Dr Percy Hlangothi, the IOM EC chairman, who also gave a presentation

Wide-ranging topics covered in lectures duel in PE FAIRVIEW Course Arena in Port Elizabeth was the location for the 14th IOM Young Persons’ World Lecture Competition in October. Sponsored by the Institute of Materials, Minerals and Mining, with support from The Armourers and Brasiers’ Company, the Young Persons’ Lecture Competition invites students and professionals up to the age of 28 to deliver a short lecture on a materials, minerals, mining, packaging, clay technology or wood sciencerelated subject. Candidates compete in a series of heats from which six regional candidates are selected to compete in the national final. Kyle Saltmarsh of Australia was awarded first place for his lecture on ‘Acoustic-based condition monitoring in the resource industry’. Second place went to Hong Kong’s Lin Guo with her lecture ‘Combating cancers with a new superweapon,’ followed closely in third place by Andrew Ng Kay Lup of Malaysia with his lecture on ‘Bio-crude oil from lignocellulosic biomass: A zero-to-hero energy scenario’. The IOM would like to thank the YPWLC major sponsor Companhia Brasileira de Metalurgia e Mineração (CBMM) for its generous support as well as IOM3 South Africa branch members for their help in organising the event.

Winners and members – from left, Naveen Tiwari (Singapore), Sam Lawton (UK), Dr Phil Bischler (IOM London), Bernie Rickinson (IOM CEO), Farirai Nyoni (Southern Africa), Andrew Ng (Malaysia), Kerry Kirkman (IOM3 Southern Africa, National Executive Chair), Kyle Saltmarsh (Australia), Alexandra Kuznetsova (Russia), Lin Guo (Hong Kong), Matheus Santos (Brazil) and Dr Kathy Garde (IOM Southern Africa)

www.iom3.org/world-lecture-competition


McLube Asia visitor points out features of effective release agents ‘It’s got to be easy and quick’ says Tapas MOULD release is one thing, mould release in an efficient, sustainable, environmentally-safe and cost-effective manner is another – and it’s in the latter category that global supplier McLube comes in. It was thus a pleasure for the KZN branch of the IOM to host a visit and presentation by Tapas Padhi of McLube Asia recently. Based in Mumbai, McLube Asia is part of the McLube division of McGee Industries of the USA which has been manufacturing high-technology mould releases and industrial lubricants since 1954. Tapas addressed the matter of mould release

agents for rubber and polyurethane. “Our products include water and solventbased release and antitack coatings and dry film lubricants. Besides the USA, we have global manufacturing locations in India and Italy. “McLube offers its release technology solution to a wide range of industries, offering different formulated coating release agents which are based on different chemistries, such as fluoro polymers, semi-permanents and fluoro-chemicals,” said Tapas, who has B.Tech (Polymer) and MBA degrees. He is business development manager for the Mumbai company.

Tapas Padhi of McLube Asia, who was the speaker at the IOM event in Durban recently, flanked by IOM KZM comm members Prakash Kalipersad and Grant Rosettenstein

In some cases achieving effective release can be complex, with the obvious objective of achieving multiple cycles. And, indeed, there is a distinction between release and removal, but whichever is practised, it should be easy and quick – and provision should be made for post-finishing operations such as painting, which should be easy and not require further cleaning. • McLube is represented by Carst & Walker.

DEC 2018 / JAN 2019 45


Associations

Waste not,

want not

The much anticipated 2018 IPSA annual seminar

46 DEC 2018 / JAN 2019

HOW can the Extended Producer Responsibility (EPR) plan to respond to the needs of South Africa and stimulate an economy that can foster meaningful work opportunities, encourage partnerships and provide a platform for transformation? This was the over-arching question on everyone’s minds during the Institute of Packaging SA’s (IPSA) annual seminar tackling the Industry Waste Management Plan (IndWMP) at the Two Oceans Aquarium this past September. The IndWMP was submitted on 4 September and the Ministerial decision is scheduled for 28 February 2019 – an optimistic date by anyone’s standards. The South African government is committed to tackling the current waste crises that our country (and the rest of the world) is facing. The IndWMP will be the foundation for this new era to begin as it will identify how specific waste streams are managed and will give the industry an opportunity to set out additional standards it will need to meet for waste management activities. The IndWMP will commit the industry to waste management targets, including recycling, recovery or reuse targets, and in some cases, collection targets, depending on the waste stream. The industry is required to report on these agreed targets to indicate the plan’s success.

individual PROs, is available to view at www.packagingsa.co.za/ industry-waste-management-plan/in However, the Waste Management Bureau, put in place by the DEA, is in favour for a government-led plan that is likely to tie up funding for the PRO’s and will lead to a decrease in recycling rates and efficiency.

Sally Ann Kasner, from JG Africa, spoke about how JG Africa was involved in the creation and coordination of the IndWMP and outlined the basic premise of the Industry Waste Management Plan in an easy to read infographic format which was cleverly put together. The proposed plan is forward-thinking in that it allows for new packaging materials that may not be on our radar yet, and for the specifically complicated supply chain that we deal with. Collaboration throughout the supply chain and redesign of how we see packaging are critical to success. Kasner continued to discuss EPR and its role as the cornerstone of the Waste Management Bureau mandate. PROs will be funded by Industry to implement their specific plans and demonstrate their responsibility. Levies on the weight have been proposed for each material based on the complexity of recovery and recycling, and these should No easy task be paid by the producers for local materials and brand owners for imported Bringing the IndWMP gazette together packaging and packaged goods. 20% of the was no easy task and the ‘dream team’ who gathered to tackle this project includes Producer money will be spent on operating costs and 80% Responsibility Organisations (PROs), Polyco, PETCO, on projects that include: Black Industrialist Scheme (a The focus is about a circular economy and The Glass Recycling Company, MetPac, Polystyrene partnership with the DTI, IDC and Waste Management not necessarily the Bureau), municipal initiatives, data collecting, national Association of South Africa, Southern African Vinyl’s hierarchy chain education and awareness campaigns, R&D and Association, Paper Manufacturers of South Africa and Packaging SA. training. The plan will generate an estimated 11 000 jobs which is a positive attribution to the country. Shabeer Jetham, CEO of Packaging SA, opened the seminar The three main functions PROs exert are: by sharing the role that Packaging SA plays in the industry. The organisation has been working closely with JG Afrika and the PROs • financing the collection and treatment of the product at the to develop an industry-led Waste Plan that will ensure that the end of its life (targeted waste streams) by collecting fees and PRO’s remain funded and avoid further levies that could impact redistributing the corresponding financial amounts; negatively on employment and inflation. The plan proposed is to • managing the corresponding data; increase the paper and packaging recycling rate from the current • organising and/or supervising these activities 57.1% to 66.9% by 2023 (the EU target is only 65%). The plan, a Kasner said that on a personal level she felt as though the IndWMP three-volume document includes a ‘Federation of Plans’ from the resonated more towards a socio-economic plan than a waste plan.


The panel of speakers included Andre Nel (Pick n Pay), Kiril Dimitrov (Mpact), Sally Ann Kasner (JG Afrika), Mandy Naude (POLYCO) and Shabeer Jetham (Packaging SA)

Andre Nel, sustainability manager at Pick n Pay, as their Sustainability Manager, explained Pick n Pay’s efforts to minimise www.packagingSA.co.za

waste, specifically plastic waste. From eliminating filler from the recycled content carrier bags, introducing paper ear-buds and free collection of recyclables from homes in some areas – Pick n Pay are making great strides in the right direction. Another initiative that Pick n Pay has created is Eco-brick stations in their stores, just one example of how the popular retailer is fighting the war on waste. Something to consider Kiril Dimitrov, MC and IPSA regional vice-chair, closed off by raising some salient points: 1. What is the next step for those not immediately involved in the development of the plan? 2. What PRO do label producers need to belong to? 3. How many plans have been submitted to the DEA? 4. Is there any plan to ban certain materials? 5. Would the plan include any contribution to Government to deal with the remaining 33% of packaging and paper waste after 2023? He ultimately suggested that the industry look to the UN Sustainability Development Goals for guidance on best practice while we wait for the plan to be finalised. www.jgafrika.com

www.polyco.co.za

DEC 2018 / JAN 2019 47

Mandy Naude of POLYCO took the audience through the challenges faced by the plastics sector PROs. POLYCO is supported by only 20% of the polyolefin, carrier bag and laminated multi material producers in the plastics industry that now generate over 600 000 tons of waste per annum. There are 200 recyclers active in the sector employing 6 000 people and generating R2 billion contributions to GDP. Currently the sector achieves a 44% collection rate for recycling. The key-driver for POLYCO is a circular economy. This means keeping resources circulating through reuse, rework or repurpose. The five-year plan submitted proposes the diversion of 550 000 ton of plastic waste from landfill, the creation of 2 500 direct jobs and the contribution of R735 million to the economy by 2023. “To achieve this we need to create new end markets and change the behaviour of both the industry and the consumer,” Mandy said. She stressed the importance of the industry working together and pointed to what is being done internationally, particularly by CEFLEX, a collaborative initiative of a European consortium of companies and associations representing the entire flexible packaging value chain. “Plastic has a place in our lives, but not in our environment,” Mandy added.


Associations

Pointers to help designers • Materials of different densities should be used to facilitate the separation of incompatible materials during mechanical shredding or crushing, or during the water-based washing process. • Combinations of different types of plastic with the same density ranges should be avoided • Fillers change the density of the plastic and should be avoided or their use minimized as they lower the quality of the recycled material.

• Unpigmented polymer has the highest recycling value and the widest variety of uses. • To decrease the amount of residue in packaging (i.e. bottles) design the bottle or pack with a wide neck, consider using a pack that can be stood to be inverted to ease emptying, and use non-stick additives to reduce the cling of contents. • Where a composite material is needed, consider the use of thin layers. • Laminates, especially those of <100 microns, are

not cost-effective to recycle. • Avoid direct printing onto PET. • Don’t use PET closures, closure liners, cap sleeves or seals on PET bottles. Rather use PP or HDPE. • Avoid using metal caps on PET bottles. • Sleeves and safety seals should be designed to completely detach from the container or else they become contaminants in the recycling process. • Use water soluble (at 60-80C) and hot melt alkali

Designing for the PETCO’s top tips on how to design easily recyclable packaging A bit over the top, but still designed for the environment – KFC partnered with food scientists to create edible cups made from biscuits, wrapped in sugar paper and lined with a layer of white chocolate. Edible packaging is a relatively new concept and could significantly reduce the amount of paper or plastic packaging used

Bottle grading system helps with design for recycling

48 DEC 2018 / JAN 2019

PETCO’s recycling programme manager, Pearl Molepo demonstrated PETCO’s new online bottle grading system which the organisation wants to pilot with convertors so it can be developed further and become a useful tool for the industry. This digital tool helps a designer or convertor to grade how recyclable their product is or will be once manufactured. The tool takes into account a myriad of factors, including colour, weight, volume, shape and plastics composition (eg. 100% PET, additives used, etc). It also takes into account the closures used, labels and sleeves, adhesives, inks, content residues and so much more. Co-extrusion technology can enhance recycling capabilities Serioplast’s Claude Naidoo, plant manager at the Boksburg factory, says his organisation are helping brand owners to become ‘more compliant’ with regards design for recycling. “We need to change the mindset of the brand owner and help them to design their packaging for the optimal end-of-life result, which is just as important as the performance of the packaging,” said Naidoo. “We also need to focus on things like ease of disassembly; how easily the packaging can be deconstructed and re-used.” “When the impact of our products on the environment are considered first in all life cycle stages of business and product processes, then, and only then, are we on the path to sustainable actions,” Naidoo added.

We live in a world where take, make, dispose – a so-called linear economy – is a way of life for many South Africans. We now know that this way of life is not sustainable. We must therefore urgently transition to a circular economy, one which looks at waste as a resource and aims to design products for the environment. This was the main focus of PETCO’s ‘Designing for the environment’ seminar held in Johannesburg and Cape Town in October. Designers and manufacturers of packaging, as well as brand owners and marketing teams gained insight into how to best design packaging that is easily recycled by the technologies Important available in South Africa. Cheri Scholtz, CEO of PETCO, to open dialogue said that designing for the between all environment is about product stakeholders stewardship, about forward-thinking in the product initiatives, about innovation and breaking new ground to achieve value chain never-before-seen solutions. ‘To design for the environment, we need to reduce the overall impact of a product on the environment before it enters the production stage. Thus, it is important to open dialogue between all stakeholders in the product value chain to increase the products that are designed more mindfully,’ she added. PETCO will be re-launching their ‘Guide to designing for the environment’ in the very near future. This guide provides guidelines for those wanting to make their PET packaging easily recyclable, including clear, concise information to ensure packaging is compatible with the available recycling infrastructure. The devastating effects that plastic six-pack rings can have to both wildlife and the environment have been proven time and time again. Here’s a look at a creative and sustainable alternative to the standard six-pack ring. Saltwater Brewery in Delray Beach, Florida, released edible six-pack rings. These six-pack rings are 100% biodegradable and edible – constructed of barley and wheat ribbons from the brewing process. This packaging can actually be safely eaten by animals that may come into contact with the refuse


soluble adhesives. • Paper labels on plastic film represent a significant problem for conventional recycling • Labels should not delaminate in the washing process. PE and PP are preferred label materials. • Foil safety seals that leave remnants of foil or adhesive should be avoided. • Heavy metal inks should not be used for printing as they may contaminate the recovered plastic.

• Inks that would dye the wash solution should be avoided as they may discolour the recovered plastic, diminishing its value. • Avoid using silica on energy drink bottles, or metal springs on dispenser bottles. • Even though there is a progressive request from retailers for RFIDs (radio frequency identification devices) to be used on packaging, they are undesirable from a recyclability point of view as the adhesives and metals reduce efficiencies and contaminate the recycling stream.

environment Beauty and the ‘bust’ Extrupet’s joint managing director, Chandru Wadhwani, explained that the National Environmental Management Waste Act directly allows for targeting of economic instruments (taxes or levies) to specific waste streams to serve as incentives or disincentives to encourage a change in behaviour towards the generation of waste and waste management by all sectors of society. Such decisions often rest with producers, who can reduce waste generation by changing the inputs and materials used in their products, or by rethinking product design.

Plant-based plastic containers – Plantbased plastics first emerged a few years ago in the food and beverage packaging industry. CocaCola, which launched its recyclable PET plasticPlantBottle in 2009, has plans to offer all of its beverages in the sustainable packaging by 2020. This greener alternative packaging uses materials that are up to 30% plant-based. Heinz began a strategic partnership with Coca-Cola, in which all of the company’s 20-ounce ketchup bottles available in retail stores and restaurants will be packaged using PlantBottles.

DEC 2018 / JAN 2019 49

HIGH THROUGHPUT. WE DRIVE THE DIAMEETS ECONOMY. QUALITY. CIRCULAR

YOUR LOCAL EREMA CONTACT RELLOY S.A. (Pty) Ltd P.O.Box 8190, ZA-1613 Edenglen www.relloy.co.za

Whether it is inhouse, postconsumer or bottle recycling: you can only close loops in a precise and profitable way if machines are perfectly tuned for the respective application. Count on the number 1 technology from EREMA when doing so: over 5000 of our machines and systems produce around 14 million tonnes of high-quality pellets like this every year – in a highly efficient and energy-saving way. That’s Careformance!

CAREFORMANCE We care about your performance.


Associations

Quality rather than quantity Creating customer confidence in the plastic pipe industry ADDRESSING the SAPPMA AGM in Midrand in October, CEO Jan Venter reiterated that the primary purpose of SAPPMA is to create absolute customer confidence in the plastic pipe industry and to ensure the long term sustainability of the industry with top quality piping systems. To this end, the Association says it is more interested in focusing on quality as opposed to quantity when it comes to growing its membership. South Africa’s watchdog when it comes to the quality of plastic pipes that are locally produced and enters the market, SAPPMA counts pipe manufacturers (large, medium and small), polymer manufacturers, suppliers of materials and services, fabricators and installers as members “Looking back at the past 12 months, we are grateful to be able to report on a constructive and fruitful year. During 2018, our main focus remained on ensuring that members meet the international quality standards and that the plastic pipes they produce continue to be of excellent quality. Only then were they allowed to clearly differentiate themselves from the rest of the market by proudly displaying the SAPPMA logo,” Venter said. The following were only some of the milestones the association reached this past year: Quality, standards, testing and certification SAPPMA stepped up the frequency and

intensity of its factory audits at SAPPMA pipe manufacturers and IFPA fabricators/ installers. According to Venter, “these audits serve as an excellent barometer of the standard of quality management by members and is indeed welcomed by most members as a very valuable, objective assessment of their operations.” He mentioned that a third round of audits is presently underway. Ensuring technical information that is up to date and relevant SAPPMA’s Technical Committee continued to fulfil an important role in ensuring that the information that is communicated to members and the rest of the industry is up to date, practical and relevant as it relates to quality, standards (national and internal), testing and certification. When more intensive investigation and resolutions were required, smaller and specialized workgroups were formed to complete the job and provide feedback. World class exposure and benchmarking SAPPMA ensured that its members enjoyed the benefits of world-class exposure and expertise by hosting the very successful Pipes XI conference in association with the International PPCA in September last year. The benefits and impact of this world class event continued to be felt as SAPPMA engaged on a regular basis with its international counterparts such as PPI of

North America, Teppfa of Europe and Pipa of Australia for benchmarking, sharing of ideas and networking. Expanding the SAPPMA brand contact and influence SAPPMA continued to pay personal visits to registered consulting engineering firms and major municipalities. throughout South Africa in 2018. These in-depth discussions centred around explaining the SAPPMA brand and service offering and has enabled the association to expand its reach to more than 200 consulting firms and more than 500 professional engineers. Looking ahead: less policing, more support Although SAPPMA still maintains contact with the SABS, most of its members migrated to the alternative routes this past year, with the majority of product testing now being performed at PESC (the Productivity Engineering Services and Consultants) and certification by SATAS (South African Technical Auditing Service (SATAS). Thanks to the development and increasing effectiveness of these two industry bodies, SAPPMA will be handing over the ‘policing role’ to the accreditation organisation, allowing it to shift its focus to that of offering a more supportive role to its members of its members, growing the market and stepping up problem solving with customers.

SAPPMA’S influence continues to grow

50 DEC 2018 / JAN 2019

Support from local certification bodies stand together THE relationship between SAPPMA and certification bodies such as the South African Technical Auditing Service (SATAS) and the Productivity Engineering Services and Consultants (PESC) continues to grow from strength to strength as these associations are increasingly supportive of each other’s efforts to ensure that only top quality plastic pipes and pipe fittings meet the international standards set by System Administration, Networking, and Security Institute (SANS) bear the SAPPMA logo of quality. “The purpose of SAPPMA is to create consumer confidence within the Plastic Pipe Industry and to promote the production and the use of high quality plastic pipes and pipes systems that meet the quality standards as stipulated by SANS or ISO. It would therefore be impossible for us to do our job without the involvement and support of organisations such as the SATAS and PESC who play a vital role in the sampling and testing of the products we send to them,” said Jan Venter, CEO of SAPPMA. In an effort to clearly differentiate SAPPMA members from non-members, the plastic pipes body announced earlier this

year that it would be increasing the intensity, and in some cases also the frequency, of factory audits. During these announced or unannounced visits by a SAPPMA quality inspector, pipe samples are taken and sent away for independent testing. Tests include checking for recycled content, internal pressure test, stress crack resistance, resistance to Rapid Crack Propagation, Melt Flow Index (MFI) etc. It is one of the prerequisites to being a SAPPMA member to allow these factory visits and for independent testing to be done on their products. Only members who are in compliance and whose products meet the SANS standard, are allowed to bear the SAPPMA mark or quality. SATAS more efficient SATAS operates as an independent Product Certification Body. It obtained accreditation to certify manufacturers to the requirements of ISO 17065 through South African National Accreditation Systems (SANAS) in 2003, and has since then made it their mission to


SAPPMA CEO Jan Venter and technical manager, Ian Venter Merit Award winners 2018, Jacques van Eck, Mike Smart and George Diliyannis

Board members for 2019 SAPPMA announced that two new board members have been elected for 2019. Don Coleman of Sizabantu Piping Systems and Terence Hobson of Sun Ace will join Jan Venter (Chairman/CEO), Mark Berry (Safripol), Vijay Naik (Flotek), Derek Faulds (Macneil Plastics) and Renier Viljoen (Rare Plastics) on the SAPPMA board. Merit Award Winners Mike Smart, George Diliyannis and Jacques van Eck received this year’s SAPPMA Merit Awards – an annual award that was instituted in 2008 with the aim of recognizing and rewarding the input and effort of individual SAPPMA members “Even though business conditions

provide an internationally acceptable South African Certification Scheme which will enable its clients to compete on the international markets by awarding certification to manufacturers of product in compliance with the requirements of the relevant SANS standard. SATAS also participates in different technical Committees for National standards and Industry associations. “It has been our experience this past year that SATAS is becoming more efficient both in their unannounced surveillance inspection and auditing of product, as well as in the feedback they give to the industry and the issuing of permits. They have highly trained, knowledgeable personnel appointed in strategic positions, that know and understand our industry and are therefore able to give valuable and insightful recommendations after they have performed their surveillance activities,” Venter explained. PESC an important productivity monitoring & enhancement company In the same way, the Pretoria-based PESC has grown into an important productivity monitoring and enhancement company that gives feedback to SAPPMA on issues relating to plastic pipe characteristics, properties and flaws they might have picked up during their product testing. The company has made a considerable

in South Africa are far from ideal, our members continue to innovate and improvise, without following the way of least resistance, namely dropping quality standards. We are very grateful for their commitment, unswerving dedication to this long term view and for their wonderful support and co-operation during the past year. We operate in, arguably, the most important infrastructural industry in the country, without adequate recognition and support of Government. Regardless, SAPPMA will continue to fight the good fight to improve and to grow the industry, bearing in mind we are doing it as a nonprofit organization, for the citizens of South Africa!” Venter concluded.

investment in new, state-of-the-art testing equipment that is compliant with the latest international standards and is currently in the process of moving to larger premises in order to deal with the growing demand for sample testing on their automated testing facilities which allow for accurate testing and quick turnaround time. “It is encouraging seeing how the market has opened up for more service providers who are able to offer certification and testing services. In previous years, we have had to deal with the frustration of long turn-round times for tests to be performed and results to be forthcoming from individuals who had little or no knowledge of the industry,” said Venter. “Samples were sent overseas at great expense to be tested despite the fact that we had local testing facilities. Understandably, serious questions were being asked about certification. The past 18 months have seen a marked improvement thanks to roleplayers such as SATAS and PESC without whom it would be impossible for us to perform our job effectively in ensuring that safety, environmental and ageing requirements of plastic pipes manufactured by SAPPMA members are met”.

www.sappma.co.za

DEC 2018 / JAN 2019 51

“SAPPMA will continue to be a voluntary, non-profit organization with a strong brand, that acts as the voice of the industry. We will maintain our focus as industry watchdog who ensures sufficiency of standards, offers technical support, coordination and marketing, but will hand over the proverbial “whip” and responsibility of conducting factory audits to an accredited organization,” Venter explained. However, he stressed that this change will not soften SAPPMA’s stance on product quality in any way. SAPPMA will also be changing the frequency of their conference events to every second year, with the next one planned for September 2019.


People

Dow names commercial leaders

to address global recycling challenges Duo to develop new business models to monetize plastics waste recycling streams around the world DOW Packaging & Specialty Plastics has announced the creation of two new senior leadership roles charged with addressing global plastics recycling and waste management challenges. Tim Boven, previously Dow’s global integrated supply chain director for Hydrocarbons, is the new recycling commercial director for Latin America and North America. Carsten Larsen, formerly Dow Industrial Solutions’ commercial director for Europe, Middle East, Africa and India, will serve as recycling commercial director for EMEA & APAC. The new Recycling commercial directors will focus on developing new business models and growth strategies to monetize plastics waste recycling streams around the world. Carsten was until recently head of Dow’s operations in South Africa. In their new roles, Boven and Larsen will be responsible for developing new business models and growth strategies that monetize plastics waste recycling streams across the Americas, EMEA and APAC. They will work with their respective commercial leadership to help design the appropriate resource structure based in the regions to advance this effort. “Too much plastic is turning into waste and entering our natural environment due to global variations in the availability of sufficient waste infrastructure, low

rates of recycling and plastic being carelessly discarded after use,” said Diego Donoso, business president for Dow Packaging & Specialty Plastics. “Dow is committed to investing in the right leaders and recycling innovations to help advance end-of-life solutions for plastics. With Tim and Carsten driving our global recycling strategy, we will be able to help our customers around the world achieve their sustainability objectives and enable the shift toward a more circular value chain for plastics.” Boven and Larsen are evaluating current plastic waste streams around the world, working to identify innovations in recycling technology that will contribute to a global circular economy for plastic. In North America and EMEA, Boven and Larsen will focus primarily on advancing the circular economy of plastic through new product offerings via technologies that will be used to transform plastic waste into valuable resources. In Latin America and APAC, where recycling infrastructure is less advanced and plastic waste continues to increase, they will focus on new recycling, collection and infrastructure platforms for Dow and its local value chain partners that keep plastics out of the environment. As part of their recycling strategy, Boven and Larsen will build on Dow’s existing collaborations, working with

Farewell to SR fundi John Lithgow Was the quiet member of the ‘rubber musketeers’ JOHN Lithgow, who spent over 40 years in the rubber industry in Southern Africa, passed away recently. He went into forced retirement earlier this year when he was retrenched and succumbed to cancer just months later. He was 66. John studied and received his Licentiateship of the Rubber Industry in the early 1970s in what was then still known as Rhodesia. He was born in the country and joined Dunlop straight from school. Dunlop was the only tyre manufacturer in Zimbabwe and hosted a strong band of formerly British adventurers/improvisers posing as rubber fundis, including Barry Hutchinson, Ron Dunwoodie, James Parks, Dave Thurlow and himself – who loosely described themselves as the ‘Rubber Musketeers’. This group of characters played a large role in the rubber industry in South Africa from then on, with John being one of the quieter players. He moved south in 1979 and joined Dunlop Industrial

Tim Boven and Carsten Larsen have been appointed to important new recycling roles, among the first by any of the international material manufacturers to do so

the company’s value chain partners to address plastic waste challenges with Dow’s technologies and initiatives that increase the recyclability of plastics. Their work will help Dow reach its 2025 Sustainability Goal of advancing a circular economy by delivering solutions to close the resource loops in key markets. “Creating these new roles within Dow is just one step of many in our commitment to advance the sustainability value of plastics,” said Donoso. “But we realize we can’t solve the issue alone, and encourage our industry peers, partners and customers to help us create and deliver solutions to stop waste leakage and maintain the value of plastics throughout its life span.”

John received the IOM³ William Sage Medal following his presentation of the Foundation Lecture in Durban in 2007

Products in Benoni, first as compound manger. He was appointed technical manager for tyres at Dunlop SA in 1984. In 1987 he joined Karbochem and was appointed marketing manager in 1995, spending the next 20-plus years involved in sales of Karbochem’s synthetic rubber materials. He was very active in overseas sales, promoting polyisoprene and was especially active in the liquid polyisoprene for golf ball production area. John laid out a lot of his experience when he delivered the IOM³ Foundation Lecture in 2007, ‘What, When and Where To?’ which focused on his observations made over the time he’d been involved in the rubber business. In 2017 he was awarded the IOM’s John Tallant Medal for outstanding service to the rubber industry and the Institute.

52 DEC 2018 / Jan 2019

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2018/11/20 12:04


People

After four decades-plus, Pinetown moulder moves over to music AFTER 43 years in injection moulding, Greg Houghton of Houghton Plastics has decided it’s time to get his feet up a bit … but no, the man’s embarked on a new venture, manufacturing guitars. And typically for Greg, who’s been virtually obsessed with design and development throughout his career (his record was the registration of 14 patents in a single year), he’s already come up with an alternative guitar design in which the sound hole is moved to the ‘shoulder’ of the instrument. Pinetown-based Houghton Plastics was started by Greg’s dad in 1970 and was one of KZN’s top injection moulding operations, running European Guitar man – Greg Houghton is now manufacturing guitars, and – just as he’s done over the past few decades – a few design variants have already materialised machinery with a wide range of products. The company was at first involved in moulding its own products design being his forté. And for Greg it’s been good: “I’ve had but moved over to custom moulding for customers, mainly fun, worked with some good people, helped develop quite a in the area of metal substitution, which was a major trend at number of products which took off, and I’m very grateful for the time. all the good times.” Greg spent three years at university pursuing three Greg’s guitar design studio is based at Nottingham successive but different academic directions, with mixed Road up on the Midlands Meander and although he’s been results, before accepting the ultimatum from Houghton Snr working at it for a number of years and manufactured a to join the business (i.e. ‘get a job boetie’). Judged by the few dozen models from the highest quality materials, with four-plus decades that have ensued since, that was surely smooth and clear acoustics, sales have yet to take off ... but the best option. He gained experience by being involved in that’s just part of this new venture in Greg’s life. every aspect of the production at the family business, with

Greg Houghton set to play a new tune

DEC 2018 / Jan 2019 53

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2018/11/19 16:29


People

Robin Rigney, new MD of Precision Valve

Marc Stevens has been appointed sales manager for Safripol Durban

Renier Snyman has joined Sun Ace SA

Ian Venter has joined SAPPMA as the body’s technical manager

NUVO Rubber Holdings’ new director, Futhi Mbanjwa

People on the move Brent Hean has been appointed CEO of eNX group’s Petrochemical Cluster, responsible for its Mobil lubricants business, base oil business Zestcor as well as West African Group, all in 150 employees. The group operates a blending plant in Boksburg. Robin Rigney has been appointed managing director of Precision Valve SA, based in Rosslyn, Pretoria. Formerly at Consupaq, the Astrapak tube manufacturing company in Durban, which he left in late-2015, Robin at first served out a restraint of trade period and developed interests outside of the industry before, late last year, joining Precision. Precision Valve is a global business with 19 plants in 15 countries on six continents. Company founder Robert Abplanalp filed the first aerosol valve patent in the USA in 1949 and the group has been manufacturing aerosol valves ever since. It also manufactures dispensing and spray pumps, actuators and caps and closures (not necessarily all in SA). Robin takes over from Alan Rex, who has retired. Safripol Durban has expanded its sales team with the appointments of Marc Stevens as new sales manager and Nolan Govender as junior representative. Stevens, who has a diploma in chemical engineering (Wits Technikon 1995), has spent his career to date in materials supply, including with Süd Chemie (specialty chemicals and systems for water treatment) from 1998-2011; Clariant (2012-2014); ImproChem, an AECI company also involved in industrial and municipal water treatment, until September when he joined up at Safripol Durban, based at its Jacobs plant. Safripol Durban (the PET manufacturer formerly known as Hosaf), like Safripol Sasolburg (HD, PP) and Safripol Piet Retief (wood chemicals), is part of the KAP Chemicals group; the businesses are in the process of realigning their systems to adhere with global polymer and specialist material

manufacture and supply standards and protocol. Renier Snyman has joined Sun Ace South Africa. Renier takes up the position of technical manager, focusing initially on South Africa. However, this role will extend to Sun Ace’s existing customers located in 16 countries across Africa where Sun Ace offers customer support in problem solving, optimising processing, cost optimisation and on-going technical support. Renier has worked in the PVC pipe manufacturing industry for over 20 years and holds a Batchelor Degree in Polymer Technology. He is 6-Sigma trained, has completed pipe design courses and has ISO 9001 training. His passion for standards of pipe manufacturing and the SANAS codes is evident through the extensive work he has done as a technical committee member of SAPPMA (South African Plastic Pipe Makers Association) and this will hold him in good stead in supporting Sun Ace’s pipe customers. Denzil Mohanlal has teamed up with Tawazon Chemical Company, a Dubai-based integrated chemicals supplier, to represent it in the SADC region. Tawazon supplies raw materials to the paint/ink, construction chemicals, packaging, fibreglass, plastic, rubber and polyurethane industries. The initial focus for Denzil and his team is primarily the ink and coatings sectors. Denzil was for long at Ferro Coating Resins (formerly Arkema/Cray Valley/ Coates Brothers), the unsaturated polyester resins/coatings manufacturer at Isipingo, south of Durban. “Having worked in the industry for over three decades, I have a high regard for the customers and suppliers and look forward to continuing my association in the sector,” said Denzil. Established over 27 years ago, Tawazon has offices in the Middle East and SE Asia as well as Nairobi. Individual products or consolidated packages are supplied direct from the country of origin or from warehouses in Dubai, Jebel Ali, Riyadh, Jeddah, Nairobi, Chennai,

Denzil Mohanlal has started Tawazon Chem SA

Bangalore and Jakarta. Tawazon Chemicals SA operates out of Durban and supplies nationally. Ian Venter has joined the Southern African Plastic Pipe Manufacturers Association (SAPPMA), who will replace Willem Liebenberg as the body’s technical manager. Ian is well known and highly regarded in the industry as an HDPE product specialist in polyethylene pressure and gravity pipe systems. He brings with him a wealth of industry and technical knowledge gained over the past 20 years working for top national and international manufacturing companies. NUVO Rubber is a company well versed in art of innovation, consistently moving beyond the expectations of the South African rubber industry. The group has completed a period of strategic focus on acquisitions and product development and are turning the gears of organisational change to maximise this investment. To manage the change and implement innovative processes, the group welcomes a new director of strategy and corporate planning – Futhi Mbanjwa. Futhi joins the group from her position as director of human resources management and development at the City of Joburg Metro Municipality (commonly known as office of the speaker of council). Before this she was instrumental in the merger of the former University of Durban Westville and former University of Natal into its current entity – UKZN. She led matters relating to the training, development and new conditions of service, producing the university’s first ever employment equity plan. As a woman of colour with a physical disability, Futhi has first-hand experience in adapting to change as an opportunity. With a master’s degree in industrial psychology from the University of KwaZulu-Natal, along with an impressive list of diplomas and management courses from the likes of the University of Pennsylvania, she has earned every bit of her success and is poised to lead NUVO into South Africa’s economic future.

54 DEC 2018 / Jan 2019

PEOPLE.indd 54

2018/11/19 16:28


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2018/09/14 11:31


Design

Thermoforming parts The Society of Plastics

SPE winners of annual thermoforming conference parts competition THE Society of Plastics Engineers (SPE) Thermoforming Division has announced the winners of its annual parts competition. “A variety of heavy and thin gauge parts of exceptional quality were submitted to this year’s competition,” noted Matt O’Hagan of the SPE Thermoforming Division’s Board of Directors. “This year’s winning entries highlighted the innovation that continues to evolve in the the thermoforming industry.”

People’s Choice & Heavy gauge pressure form

Profile Plastics for ‘ medical cart enclosure’

GOLDD R AWA

The medical cart is an innovative surgical system providing flexibility during various surgical procedures. The primary cart unit consists of seven pressure formed enclosure parts, and the secondary cart unit consists of three pressure formed enclosure parts, both using PC-ABS material to meet a stringent rigidity, chemical, heat and highly cosmetic requirements. Customer parameters required zero or minimum mechanical attachment features which presented many unique forming challenges. Many of the attachment features were innovatively mouldedin to meet the customer’s requirements. Bonded-in fastening features on the non-cosmetic side of the part were also required to be kept at zero or at a minimum. The final design incorporated numerous movements on each tool to provide fastening features as well as cosmetic finished seams. The primary cart’s interaction between the rear top cover and the side covers presented numerous challenges to achieve a hidden fastening system and maintain cosmetic alignment between the parts. Complex core pulls were used on the upper cover to incorporate slots for a work surface table. While the secondary cart’s large front cover presented numerous challenges with 4-way undercuts due to the extreme draw depth. The final design on this part allowed the elimination of additional side panels and reduced overall tooling cost. With the application being used in a surgical environment, the customer also required stringent and detailed validation and thorough quality procedures and documentation.

Budweiser brings smart-packaging to Circuitry built into cup responds to sound with LEDs that flashed – By Kate Bertrand Connolly in Smart Packaging ANHEUSER-Busch InBev, no stranger to innovative packaging design, outdid itself at the 2018 FIFA World Cup tournament in Russia, with collectible Budweiser cups that lit up in response to crowd noise. Circuitry built into the beverage packaging responded to environmental sound with light-emitting diodes (LEDs) that flashed, visually ramping up the fans’ energy. The cups had two levels of activation, so louder noise amplified the already flashing lights. The brand owner’s Global Innovation 56 DECEMBER 2018 / JANUARY 2019

and Technology Centre (GITEC) in Leuven, Belgium, which created the 500ml beer cups, also took an ambitious approach to graphic design. The graphics on each cup were keyed to the match during which the beer was sold, featuring, for example, the competing countries’ names and flags that was done using inmould labels (IMLs). Anheuser-Busch InBev created more than 70 versions of the cup to incorporate imagery from the many countries that

participated in this year’s World Cup. It produced more than 8 million cups altogether. For fans purchasing multiple cups of Budweiser at the 12 World Cup stadiums, Anheuser-Busch InBev provided easy-to-transport cup carriers. The cups were made using polypropylene as the clear cup design and label combination give an icy frosted design to the glass when filled with beer, to drive visual appeal. The polymer also keeps the beer colder longer, versus


– winning designs

Engineering annual parts competition Roll Fed Consumer

Roll Fed Innovative

Placon for ‘Pokemon tray’ The trading card game package includes a rigid setup box with printed litho foil paper wrap with three RPET thermoformed trays inside made with environmentally conscious EcoStar® recycled PET material. The versatile packaging configuration is intended for retail, but also converts into a storage device for players after the content is unpacked. The plastic clamshell in the cover allows GOLDD for high level R AWA promo cards to be displayed in the front of the box for retail presentation, and also allows consumers to change the cards to include their favourite cards to display. The magnetic closure on the front panel helps to keep the outer box closed and the product protected. Due to the package design, the product resulted in cost savings. The design reduced material thickness, allowing for multiple trays to be stacked together in one box. The design highlights the promo cards which can only be purchased in this box, front and centre in a thermoformed tray. This window allows the consumer a sneak peek at additional contents in the box, contributing to product image and shelf impact.

Placon for the ‘nametag organiser’

GOLDD R AWA

The customer requested a thermoformed tray that would house several shaped name tags and help them reduce freight costs. The design is a sustainable, thermoformed tray made from Ecostar® recycled PET material to organise, ship and display name tags for large meeting registrations. A distinctive design innovation of the die cut shape allows for multiple tray configurations to house several name tag shape variations. • The dual-purpose snap fit closures connect two trays together to house 100 name cards, doubling capacity over the existing product. • Simply unsnap the closures to separate the two trays and you have immediate set-up for two registration lines by alphabetical order. • Bend the tray along the middle perforation and secure the side tab locks to hold the tray in place. Name tags with identification ribbons attached fit securely in the retention card pocket along the short side for easy display. The unique perforation allows the tray to fold into a square and the snap fit closure locks securely to hold the square configuration in place for safe storage and easy transit in a box with carrying handle. The retention card pockets hold the name tags snugly in the slot so no tag will slide out of place. The trays were designed with offset card slots for interweaving when the trays are folded into a square. The tray design allows for company branding with an engraving area along the top perimeter of the tray.

FIFA World Cup The base is a translucent Budweiser red to maximize the impact of the LEDs, and the cup itself is clear. The component sandwich locks together in a unique design that can’t be opened by the consumer without the use of a tool. This was a specific requirement of FIFA and required borrowing the best snap-fit technology known in the injection-moulding industry. The cups had to be lighter than a cell phone, shatterproof and not come apart into small projectile components by human force.

DECEMBER 2018 / JANUARY 2019 57

aluminium, during the game to enhance the experience. The material as well as the lip-edge design resulted in a very comfortable, pleasant experience. The nine LEDs in each cup are activated by changes in sound level. Algorithms are listening for decibel patterns and the cup reacts visually in the moments corresponding to celebrations, excitement and high energy. A few different patterns of light are displayed accordingly. The PCB is sandwiched between two injection-moulded components.


Design Roll Fed Innovative

CMI Plastics for ‘Knob Creek POP display tray’ ER SILV RD AWA

Roll Fed Food

58 DECEMBER 2018 / JANUARY 2019

Global Plastics for ‘egg carton’ This unique tray features a Knob Creek 750ml bottle, one Bitters bottle (50ml), one box of sugar cubes (42.5g) and one muddler. The tray design proposed by the customer was to have a rigid thermoformed tray from HIPS with a printed SBS mask applied. The proposed tray alternative eliminates the need for a printed mask, saving both material and assembly cost. The design further enhances the appearance of the final shelf presentation with a realistic representation of wood grain barrel slats used for whisky. The tray is comprised of a coextruded ABS which provides better structural properties over the proposed HIPS design. 60% is recycled utility black and 40% is colour match brown. This mix was carefully engineered with the goal of a natural gradient of black and brown colours, giving the tray a natural weathered look. The design aspect of the wood grain was achieved though reverse-engineering natural wood to pattern the surface. The master patterns were sculpted and sampled to ensure the proper look and manufacturability using aluminium cast moulds. Designing and forming proper undercuts posed the biggest challenge. The final presentation required no window on the carton. Each cavity not only had to hold the product snugly, but had to deter pilferage.

GOLDD R AWA

This 100% recycled PET egg package is an innovative container that will revolutionise the egg packaging industry. Other PET egg containers fall short as a substitute for styrofoam because of their inability to efficiently flow through the automation equipment which is used by most farms today. This package eliminates that problem as it was designed for exactly this purpose. Stores are demanding recycled PET, but no container until now has been able to give the farms the ability to both provide eggs in PET while simultaneously being cost-conscious and meeting production requirements in the filling stations. The clamshell, hook-locking, package is formed from 18mm x 29.5mm 100% recycled PET sheet rolls. The package has 12-count, 18-count, and 24-count versions, as well as a topper for the 60-count bulk pack. The package is currently offered in clear PET (made from sodas and water bottles) and green PET (made from 7ups, Sprite. Mountain Dew) and will soon be rolling out in amber (made from root beer and iced tea bottles). Unlike pulp or styrafoam egg packaging that requires printed on labelling, this package gives egg producers the ability to simply interchange the label to meet the customisation needs of their clients. The design of the package also ensures that eggs are secured during transportation, drastically lowering the amount of breakage.

Heavy Gauge Vacuum Form

Fibre Pad for ‘bass boat driver console’ This shroud covers boat driver and passenger consoles and provides a surface to mount a windshield. The body of the shroud is vacuum formed with a custom built machine that uses a ‘wrapping’ method which provides additional capabilities with larger undercuts than normally permitted with standard vacuum forming machines, and material thickness to the overall part. Then it is trimmed on a 5�axis CNC router. Material used is an ABS with a decorative laminate that provides UV resistance and texture. Because of the difficult geometry, shrouds like this have been made using fibreglass. In an effort to lower boat weight and reduce carbon footprint, this part, among others, were identified as a candidate for plastic replacement. Controlling mould temperature was instrumental in reducing and removing chill marks.

GOLDD R AWA



Design Heavy Gauge Pressure Form

Ray Products for ‘medical device cover’

GOLDD R AWA

60 DECEMBER 2018 / JANUARY 2019

ER SILV RD AWA

During its prototyping and approval process, a medical device manufacturer used urethane casting to create the panels for its medical device enclosures. However, it was limited by manufacturing capacity, high per-part costs and issues with part-to-part consistency. By switching from urethane casting to pressure forming, the medical device manufacturer was able to significantly lower costs, improve manufacturing speed, increase durability and guarantee part-to-part repeatability. The design company worked closely with the thermoforming company’s manufacturing team and the medical device manufacturer’s engineering team to make sure they were getting the most out of the process. This meant reducing the total number of bosses, designing in undercut features for rigidity and improved fit, as well as working in other attachment points to lower the total manufacturing and assembly costs, while improving aesthetics. To achieve the undercuts and tight tolerance parts required, the thermoformer used machined aluminium tooling that is temperature controlled with actuating slides. High quality tooling also allows for the tools to be textured when the time comes for moulded in colour opportunities. Starting with tooling that will achieve part-to-part repeatability is important when you are using 6-axis robotic trim centres to complete your production parts.

Heavy Gauge Twin Sheet

Therma-Hexx for ‘hydronic heat transfer panel’ ThermaPANEL is a hydronic, modular heat transfer system for heating and cooling exterior and interior environments and surfaces. It is primarily used for highly efficient snow melting of pedestal and ground-mounted pavements and for collecting solar energy to heat swimming pools while cooling the pool patio, not achievable with tube-based systems. The ThermaPANEL units are twin sheet thermoformed using PE-RT plastic on a shuttle type thermoformer with production moulds allowing for the creation of a multi-channel panel with flow turbulation stanchions and inlets that allow for even, turbulent flow of the hydronic fluid throughout the modular panel. The result is an enhanced, conductive or radiant heat transfer between the panel and any surface that it is in contact with. The 110” material is extruded into individual sheets and is corona treated on one side to allow for better adhesion of the PSA adhesive that holds 1” of EPS insulation to the bottom of the panel. The temperature-controlled tooling forms an inlet and outlet near the centre of each panel allowing for the secondary process of the socket fusion connection of 1/2” PE-RT “S” shaped tubes between the panels which in turn create foldable rows of pre-assembled panels up to 50’ long. The socket fusion process rounds out the imperfectly thermoformed inlets. After forming, the panels are cooled to a specific temperature allowing for a predetermined shrink and then trimmed on a 30-ton stamping press with a 3D die. The design of the cutting die was critical for trimming around the inlets while allowing for a variance in size due to shrink. A proprietary pressurized testing unit had to be created to be attached and sealed to the roughly-formed inlets. After trimming, the panels are immediately pressure and heat tested in ovens providing the thermoformer with immediate results for QC. The thermoforming, cooling, stamping, testing and re-grind process are performed by one person. An automatic loading double end thermoformer is being built to cut production cycle time by more than 60%.

Heavy Gauge Twin Sheet

Allied Plastics for ‘bear-resistant lid for a roll out cart’ ER SILV RD A AW

Designers created this lid to keep bears from gaining access to roll-out carts. The lid is twin-sheet formed to provide a structurally rigid assembly for the enclosure of a 95-gallon garbage can cart. By using the twin sheet process, the design team was able to make a much stronger lid but also have some flexibility when the bear would try and get into the cart. Upon release, the plastic immediately returns back to its formed state, not allowing the bears to gain access to the contents inside. The twin sheet lid is formed from 0.125”/0.156” HMWPE. The tool is a 2-cavity water-cooled, cast over-sized, 100% machined aluminium mould with a chemically etched texture. www.thermoformingdivision.com


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Introducing the Objet500 Connex3 from Stratasys, the world’s only full-color and multi-material 3D printer. Select from incomparably brilliant and consistent colors, plus a full palette of transparent colors — the only 3D printer to offer such a wide array. And it’s the only 3D printer that prints flexible materials in a broad range of shore values. All with ultra-fine detail creating the most true-to-life modeling possible. Stratasys is the proven leader in multi-material 3D printing. For whatever your mind can imagine, visit stratasys.com/Objet500 Connex3.

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2014/03/26 8:33 PM


Design The student participants, with former SPE Thermoforming Division chair Mark Strachan in front of group. Ryan Fuller and Karina Patricia, the winning team from Georgia Tech, are kneeling, and Ryan (in the orange shirt) is holding the winning entry

Student radio controlled car race & design competition Encouraging students to consider a career in thermoforming by engaging them in a fun design project

62 DECEMBER 2018 / JANUARY 2019

THE Society of Plastics Engineers (SPE) Thermoforming Division has selected the winners of its inaugural student radio controlled car race and design competition. Students from six schools in the US and Germany were charged with designing, manufacturing and decorating the bodies of radio controlled cars furnished by the division with support from corporate sponsors. The car body had to be formed using clear plastic, such as PET, PETG, acrylic or polycarbonate and produced using the vacuum/thermoforming process.

Students also participated in a race conducted on a built-to-specification indoor racetrack located on the exhibit hall floor during the Thermoforming Division’s annual conference in September. The winners were: • People’s Choice; Best Design and first place in the race: Ryan Fuller and Karina Patricia, both of Georgia Tech. • Second place in the race: Max Schoch, ILLIG Apprentice Program. “The goal of the competition was to

The custom-extruded race track designed and fabricated by Mark Strachan

www.thermoformingdivision.com

encourage students to consider a career in thermoforming by engaging them in a fun design project,” noted Mark Strachan, former SPE Thermoforming Division Chair and organizer of the Student RC Car Race and Competition. “The students’ enthusiasm for this project was contagious, and it was especially rewarding to see the students forging those all-important connections with their corporate sponsors. We expect even greater student and corporate participation in future competitions.”


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Equipment

Nissei ASB introduces

PF36 family High efficiency, extremely compact bottle moulding machine BUILDING on the success of the PF24-8B 1.5 Step injection stretch blow moulding machine first launched at K2013 in Düsseldorf, Nissei ASB recently debuted the first of its new PF36 Series at China Brew & Beverage 2018 in Shanghai. The new model line-up extends the range and capabilities of the platform providing higher productivity and even greater efficiency. The 1.5-Step moulding process Traditionally, PET bottles are made either by the 1-step or 2-step moulding processes. Depending on the container type and local market conditions, each process has its own merits. As the world’s leading one-step machine manufacturer, ASB recognised the merits of each system and, in 1995, combined them into a pioneering moulding system that became known as 1.5-step moulding. In this process, preforms are injected in a greater number of cavities, partially cooled to maximise stability then temperature conditioned before being passed to a blow mould containing 1/3 the number of cavities of the preform mould. Since it normally takes around three times longer to injection mould a preform than to blow a bottle, this means that each part of the machine operates at maximum utilisation and investment costs for blow moulds are reduced.

family of PF Series of machines, preforms are injection moulded in batches of up to 36, then partially cooled to provide a stable starting point for the rest of the process. Preform temperature is then raised and optimised in a continuous flow heating oven before being passed to the blowing station for re-heat stretch blow moulding. The result is an extremely compact bottle moulding machine that operates at high efficiency and produces the highest quality of finished bottle because, as in the one-step system, preforms are never released, eliminating risk of scuffing or neck deformation. To achieve the same output by two-step moulding at least 2-3 times the factory floor area would be required, product handling costs are increased, and the container visual and neck quality would be significantly lowered. Additionally, by blowing the bottle within the same machine that moulds the preform, risk of contamination is eliminated and the

hygiene of the bottle is assured, making the machine ideally suited to an in-line filling operation for beverage products. The model shown at ChinaBrew was the PF36/36-600 denoting that it moulds 36 preforms per cycle and is capable of moulding bottles up to 600ml capacity. Blow moulding is carried out by an integrated 12 cavity linear blow system that operates three times per injection moulding cycle. Other models built on the same platform include: • PF36/24-1500 – 24 preforms and 8 blow cavities up to 1 500ml • PF36/18-2000 – 18 preforms and 6 blow cavities up to 2 000ml • PF36/12-5000 – 12 preforms and 4 blow cavities up to 5 000ml There are also systems currently under development at ASB that will use the same moulding principle for PET bottles up to 20-litres capacity.

64 DEC 2018 / JAN 2019

Preforms are injection moulded in batches of up to 36 In this latest iteration of the successful

Vison1 Control System The Nissei ASB model shown at ChinaBrew was the PF36/36-600 denoting that it moulds 36 preforms per cycle and is capable of moulding bottles up to 600ml capacity. Blow moulding is carried out by an integrated 12 cavity linear blow system that operates three times per injection moulding cycle


500ml bottles exiting the 12-cavity blow mould

Increases productivity by around 50-80% Compared to the previous PF24 model, the new PF36/36-600 has a footprint that is just 30cm longer but increases productivity by around 50~80% from around 9,000bph up to 14,000~17,000bph depending on the container specification. Part of that increase comes from increased cavitation, but dry cycle time has also been significantly reduced in the blow station, while further developments in preform cooling have seen reductions of up to 30% in injection cycles over previous models. Efficient hybrid functions The injection unit and injection mould clamping are hydraulically operated, using low energy consumption variable displacement pumps, but downstream from there all major movements are driven by servo motors including the blow mould clamp and stretching, while pneumatic

36-cavity injection mould

operation is reserved for the small and simple motions. The result is a remarkably low actual energy consumption of just 66kW to mould a 500ml bottle at an output more than 14,500bph. With the linear blow moulding system operating at three times per injection cycle, for small light weight bottles where theoretical output may exceed 17 000bph, the linear blow system may need to operate at sub 2.5 second cycle times. In combination with the servo driven systems, ASB’s recently introduced Vision1 machine control system provides high speed, smooth and synchronized control of multiple movements that enables these cycle times to be easily achieved while ensuring incredibly low noise and vibration. Advanced injection Where light weight preforms are being moulded in short cycle time, the screw www.nisseiasb.co.jp

charging recovery can be a limiting factor on minimising cycle time, so as a countermeasure, a holding pressure cylinder is mounted on the front of the injection barrel that maintains pressure within the cavity, allowing screw recovery to occur simultaneously thus ensuring the shortest possible cycle time is achieved. Vison1 control system The model line-up features ASB’s new advanced control system, dubbed Vision1. This industrial PC-based system provides a long list of advantages for potential users of the PF36 Series, one of the key points being improved system integration over dedicated PLC systems which enhances machine cycle efficiency and control precision – vitally important in the highspeed movements in the blow station. • Contact Nissei ASB South Africa (Pty) Ltd at Tel: 012 345 4924 DECEMBER 2018 / JANUARY 2019 65


Equipment Sizabantu Piping Systems’ Renier Van Wyk next to the ZRS series pipe shredder with Zerma’s Jeff Cawcutt. Zerma have successfully installed over 125 pipe shredders since the first machine over a decade ago.

Zerma install

mammoth horizontal shredder, and more

66 DEC 2018 / JAN 2019

Zerma first to conceptualise, manufacture, install horizontal pipe shredders for 7500mm lengths JEFF Cawcutt and his Zerma Africa team are grateful to have had a busy couple of months, installing several Zerma shredders and granulators around the country. Sizabantu Piping Systems, established in 2002 as a specialist supplier of plastic piping to the civil, industrial, mining and agricultural sectors; and having grown from strength to strength, partnered in 2012 with Molecor Canalizaciones of Spain, the acknowledged world leader in the production of bi-axial orientated PVC pipe (PVC-O). With Zerma’s experience in the pipe recycling sector as the first to conceptualise, manufacture and install horizontal shredders for long lengths of large diameter pipe, Sizabantu decided Zerma was their first choice for the project. As one of the largest independent

electrical distributors in Southern Africa, Dynamic Distributors understands the electrical wholesale market and what it takes to be an industry leader, which includes a clear focus on manufacturing and recycling their in-house waste. Having operated a Zerma GSC series granulator for over 14 years, it was time to partner their original granulator with a Zerma ZBS series shredder to also process their in-house lumps and purgings. The machines are connected by an intermediate conveyor and integrated to ensure optimum production while avoiding overfeeding. For over 40 years, Vacuform 2000 has been a leading manufacturer of technical blow-moulded and vacuum-formed components for the automotive industry, now in a JV with the global giant Motherson

Below left: Lee Bloxam of Dynamic Distributors and Chantal Shaw of Zerma Africa with the Zerma ZBS series shredder that will be used to process Dynamic’s in-house lumps and purgings

Sumi Systems Limited. Supplying high quality parts such as cockpit and console ducts and window washer and radiator expansions bottles, requires technical know-how, experience and machinery that keeps pace with the rigorous demands of the automotive industry. With their latest installation of Zerma in-line granulators, Vacuform is able to immediately return production waste back to their blowmoulding machines. In addition to the standard features, these granulators are fitted with multiple cooling devices, high temperature conveyor belts with all-metal detectors, are fully soundproofed, include de-dusting systems, energy saving devices such as soft-start and torque monitoring, and several other options to optimise the recycling of the thick, high temperature parts. Below Right: With their latest installation of Zerma granulators, Vacuform has closed the loop on their recycling operations. Seen here at one of the granulators is Max Paeslack of Zerma, Bradley Legodi, Kenneth Mthethwa and Ryan Ravenscroft of Vacuform.

www.zerma.co.za


- passionate about the plastic industry.

Tel: +27 11 824 3103 - Fax: +27 11 824 6018 email: sales@sescc.co.za - www.sescc.co.za Unit 1, 16 Davidson Place, Wadeville, 1428

Supplier of:

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Rebuild

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News

The choice of

The gravimetric dosing unit SPECTROFLEX G operates seamlessly with many components of the successful volumetric dosing system

gravimetric or volumetric motan-colortronic combines volumetric or gravimetric dosing on one unit

The SPECTROFLEX V from motancolortronic is a modular, extremely flexible volumetric dosing system for powder, granules, pellets, regrind, flakes and fibres. The modular design enables optimized individual adaptation. With just a few hand movements, the dosing unit can easily be adapted to different material properties. There is now a gravimetric dosing module available for the SPECTROFLEX V. It uses the same base and the same exchange modules as the SPECTROFLEX V and is also suitable for granules, regrind, powder and flakes. Depending on the feed material and the unit version, throughputs of 0.7 to over 3000 litres per hour are possible with small dosing tolerances. Free-flowing and non-free-flowing materials can be dosed. Due to the same technical basis of the volumetric and graviteric systems, little training is required for production or to switch between materials and the two dosing technologies. Thanks to the available exchange modules there is no cleaning time 68 DEC 2018 / Jan 2019

required for material changes and the changing of the set-up is quick and easy. The gravimetric dosing unit is controlled via GRAVInet SF. This is a networkcompatible control for up to two dosing modules. The precise DMS load cells are equipped with separate amps and CAN-bus interfaces – making them perfect for use in modern production environments. • GreenTech Machinery represent motan in SA The exchange modules of the SPECTROFLEX can be exchanged with just a few hand movements

www.greentechmachinery.co.za

www.motan-colortronic.com

Rapid Granulator Appoints New Distributor for South Africa Appoints New Distributor Rapid Granulator for South Africa

Effective from December 15th 2016, Rapid Granulator AB, the Swedish-based world leader in plastics granulation Effective fromhas December 2016,Consulting, Rapid Granulator AB, technology, signed15th up FdB Johannesburg, the Swedish-based world for leader plastics granulation as its sole distributors theinSouth Africa and Subtechnology, has signed up FdB Consulting, Johannesburg, Sahara Market as its sole distributors for the South Africa and SubSahara Market

Regrind Material Bin Regrind Material Bin

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CONSULTING (Pty) Ltdappointed Agents CONSULTING appointed Agents

Frank Blues Frank Blues Stronger than ever Engineering EngineeringDesign Design High value processing of films fibers in-house production scarp and wasted post scarp and wasted post in-house fibers PE, films processing High value PPS PP, PS,production materials: waste.ofFor consumer

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2018/11/20 2018/05/28 12:19 11:14



Web

Online analytical tool calculates ROI for advanced sheet die

70 DEC 2018 / JAN 2019

Designed for fast changes in thickness NORDSON Corporation has developed a digital tool for comparing the cost inputs of standard sheet dies with removable lower lips and those of the EDI® SmartGap™ mechanism for rapidly changing sheet thickness. The tool, called the SmartGap Payback Analysis, enables sheet manufacturers to calculate the payback time for switching to SmartGap technology. It can be accessed online at www.nordson.com/en/divisions/polymer-processing-systems/ support/calculators. SmartGap technology enables manufacturers to make changes in thickness with unprecedented speed, extend the range of thicknesses that they can produce, and achieve these improvements while enhancing sheet quality. The system uses a single-point adjustment mechanism that changes the lip gap while simultaneously modifying the length of the lip land to provide the most appropriate conditions for the newly adjusted thickness as the sheet exits the die. By mechanically linking the adjustment of these two key

process variables, the SmartGap system ensures a proper set-up of the die and takes substantial time and guesswork out of the process for achieving desired sheet properties. Users of the SmartGap Payback Analysis enter two types of information: 1) the one-time costs of equipment investment for a standard sheet die with removable lower lip and for a new SmartGap system; and 2) process data including die length, output rate, number of die gap and die lip changes, number of working days, raw material cost, approximate product selling price, and burden cost of sheet line per hour. Using these inputs, the tool calculates the daily output values of the two systems, including downtime, missed production output, downtime cost, missed product gross profit, and total downtime cost; compares the time required for changing die lips versus that needed for changing the die gap in the SmartGap system; and estimates the how long it would take for a complete return on an investment in the

SmartGap system. “The SmartGap system eliminates the extended shutdowns for changes in lip components that have often been necessary when transitioning to new job runs, reducing to a matter of a few minutes’ changeovers that used to take two hours or more,” said Iuliano. “Also overcome are previous limitations on thickness range caused by the complexities of die modification; the SmartGap system readily encompasses die gap adjustments over a range of 0.400 in. (10.2 mm), enabling processors to efficiently run with multiple product changes per day. At the same time, the SmartGap system enhances product quality and consistency, in part by keeping the lip faces and lip lands parallel while carrying out changes in thickness.” www.nordson.com

Afritrade launches new website

Taigan’s new website highlights t-nano33 stretch wrap

Afritrade Machinery Importers based in Durbanville outside Cape Town, have launched their newly designed website, www.afritradesa.co.za. The goal with the new design is to create a user-friendly browsing experience for trusted and valued customers and business partners.

TAIGAN M-Stretch has revamped their website and included an eyeopening video about the capabilities of its t-nano33 stretch film. Once on the homepage at www.taigan.co.za, scroll down to watch the video. If you’ve not properly palletised your goods, you could be one of the 4% of damaged shipments that are estimated every year through the many logistical channels. T-nano33

is the next generation in load stability and safety. The 33 layer stretch is stronger, thinner and more stretchable, extremely strong as well as puncture and tear resistant. Less film is required, reducing wrapping yields and therefore creating a significant cost saving. It also ensures more secure product loads, which will ultimately reduce the risk of damage in most shipping conditions


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2018/04/05 10:22


World News

Covestro supports

sustainable urban development Innovative material solutions for energy-efficient solar houses

ONGOING urbanisation brings with it many challenges, especially in megacities because they’re currently developing in countries such as China. Above all, solutions are needed that reduce the energy consumption of buildings and vehicles. The Chinese government is now promoting sustainable urban planning concepts and a wider use of renewable energies. This is the goal of Solar Decathlon China, a student competition for building concepts that use only solar energy. The venue for this year’s ‘Olympic games for solar energy and green building industry’, as the organisers call the Decathlon, is the city of Dezhou. It is also known as the Sun City because it’s at the centre of the Chinese solar industry. 22 student teams from 37 universities from around the world will take part in the competition. With know-how and material solutions, Covestro supports two student groups in the competition – the joint team of Tongji University Shanghai and TU Darmstadt, and the team Shunya of the Indian Institute of Technology in Mumbai. Megacities as a challenge and opportunity “The fast-growing megacities in these two countries present particular challenges

to population supply, the development of the infrastructure and climate protection,” says Dr Markus Steilemann, CEO of Covestro. “At the same time, local universities and companies often develop the best solutions for global trends such as progressive urbanisation.” Therefore, close cooperation with local partners is particularly important: “Together with them, we develop innovative and sustainable material solutions for energyefficient buildings. On that basis we want to help shape future habitats and make the world a brighter place,” says Markus Steilemann. With projects like this, Covestro is committed to achieving the 17 Sustainable Development Goals (SDGs) of the United Nations. Particular priorities are sustainable cities (SDG number 11) and the use of renewable energy (SDG number 7). Solar Decathlon China: holistic residential solutions in demand Each team was to design and build a one- or two-story solar house with a floor space of between 120m2 and 200m2. The solution is evaluated according to ten criteria: architecture, market appeal, engineering, communications, innovation, comfort zone, appliances, home life, and

commuting and energy performance. In August, the winning concept was announced and the area will be turned into a permanent exhibition for sustainable construction and into the first intelligent low-carbon park in China. Sophisticated construction concepts The EnergyPLUS Home 4.0 from Tongji University and TU Darmstadt has a modular structure, so that several units can be combined to form an apartment building. Covestro produces transparent and heat-insulating polycarbonate panels for the façade, as well as polyurethane raw materials for waterbased, yet waterpermeable outdoor floor coatings. They are a perfect fit for new city drainage systems like so-called sponge grounds that soak in water and direct it into piping systems underground. Mumbai’s Shunya team’s Solarise concept combines regional architectural principles and includes climatic and cultural aspects. It is a net positive energy solar villa with a floor space of 150 square meters, which is suitable for

Closing the polystyrene recycling loop A TRIO of companies are joining forces in a project they say will close the loop on polystyrene recycling, and a representative for one of the partners believes the approach will fundamentally change how PS is viewed in the recycling market. ReVital Polymers Inc of Sarnia, Ontario, will use Pyrowave Inc’s Catalytic Microwave Depolymerisation technology to create monomers that will be used by Ineos 72 DECEMBER 2018 / JANUARY 2019

Styrolution. Pyrowave uses microwaves for ‘fast depolymerisation’ within units that will be able to process 50-100kg per 30-minute cycle. These units will be able to handle between 400 and 1 200 tons per year, and an operator such as ReVital can operate many on-site units depending on need. The equipment converts mixed plastics, with or without food contamination, into

predominately oil containing valuable waxes and monomers. These products are sold to chemical companies that reuse the monomers and waxes.


The EnergyPLUS Home 4.0 from Tongji University and TU Darmstadt has a modular structure, so that several units can be combined to form an apartment building

a family of six people comprising all modern amenities for comfortable and sustainable living. Products from Covestro are used in insulating polycarbonate panels on the roof, in polyisocyanurate insulation panels in walls and floors, and in the coating of the steel framework. In focus: renewable energies “With the support of the Solar Decathlon China, Covestro also underlines its commitment to the expansion of renewable energies such as solar and wind power,” says Dr Christian Haessler, head of Sustainability at Covestro and former head of its Polymer Research and Development Centre in Shanghai. The company was the official sponsor of the Solar Impulse project of the pioneers Bertrand Piccard and André Borschberg, who for the first time circumnavigated the earth with a solarpowered aircraft. The students from the RWTH Aachen University, who participated in a self-built solar car at

Pyrowave has a demonstration unit operating in Montreal, but this will be the first full-scale commercial operation of the technology. The unit is expected to be up and running during the second quarter of 2019. Pyrowave’s technology is built in a 40-foot container that can be placed at

the World Solar Challenge 2017 in Australia, arguably the toughest solar race in the world, were supported. “Covestro is also involved in expanding wind power, especially in China,” adds Christian Haessler. “Together with partners, we developed new polyurethane composites for rotor blades of wind turbines. These are more flexible and robust than conventional blades and can be made faster and more economically.” Worldwide competition for solar construction The first Solar Decathlon events took place from 2002 in the USA. Later offshoots were also established in other regions. The initiator and organiser continue to be the US Department of Energy. This year’s Solar Decathlon China will also be hosted by China’s Ministry of Energy and other national authorities. www.covestro.com

recycling facilities to handle the PS stream. Polystyrene, both expanded and rigid forms, is recycled, but not as extensively as fellow resins PET and high density polyethylene. EPS, in particular, is in a fight for its life in some communities which believe the material cannot be effectively recaptured and recycled.

The equipment converts mixed plastics, with or without food contamination, into predominately oil containing valuable waxes and monomers. These products are sold to chemical companies that reuse the monomers and waxes

Engel holds steady despite global economic uncertainties DESPITE a slowdown in North America amid trade uncertainty, Engel Holding GmbH expects global sales to reach around $1.85 billion for fiscal year 2018-19, marking a 6% increase in earnings over last year. Global sales for the 2017-18 fiscal year ending March 31 were $1.74 billion, up 11% from the prior year. The Austrian maker of injection moulding presses, robots and automation systems cited Europe as the biggest contributor, making up 53% of the company’s sales, followed by the Americas at 24% and Asia at 22%. Germany, specifically, continues to post the highest sales. Over the last five years, Engel has increased its sales by 50% in the country, where it employs 340 people.

AROUND THE WORLD

Covestro supplied transparent and heat-insulating polycarbonate panels for the façade of the building from Tongji University and TU Darmstadt

THE United Nations has launched a ‘global plastic platform’ to fight plastics waste worldwide. The platform aims to encourage new commitments to reduce plastic pollution and explore innovative ways to change the habits of design, production, consumption and disposal of plastics around the world. The aim is to provide support to countries and cities with ambitious environmental commitments, by facilitating the sharing of experiences and the establishment of new policies. Also addressing the session, European Commission’s First Vice President Frans Timmermans presented the EU Plastics Strategy and legal proposals to tackle single-use plastics as a gold standard, inviting government and industry panelists to work together to find solutions for transition to a circular plastics economy. Under the new EU plans, all plastic packaging on the EU market must be recyclable by 2030, the consumption of single-use plastics will be reduced and the intentional use of microplastics will be restricted. In May, the EC detailed a draft legislative proposal to ban ‘single-use’ plastics, including nonrecyclable plastic items such as straws and balloon sticks as alternatives already exist in the market.

Clariant, Sabic to merge part of materials portfolio SWISS materials supplier Clariant AG and Saudi chemical company Sabic are to merge parts of their businesses in a bid to create a leading supplier of high-performance materials. The move follows Sabic’s takeover of a 24.99% stake in Clariant last month and builds on their previous Catalyst joint venture Scientific Design between the two companies. Clariant announced in September that it had signed a memorandum of understanding with Sabic to combine its additives and high value masterbatches – colour, high temperature resins and health care – with parts of Sabic’s specialties business. The deal doesn’t include several wellknown Sabic materials that originated with GE Plastics. Materials remaining with Sabic include Lexan-brand polycarbonate, Cycolac-brand ABS, Cycoloy-brand PC/ABS, Valox-brand PBT and Xenoy-brand PC/PBT.

DECEMBER 2018 / JANUARY 2019 73

es o

UN launches global plastic pollution project


World News

CFRP injection moulded composite replaces aluminium in oil control valve Metal-to-composite conversion reduces cost, weight, improves engine performance AN Asian automaker has replaced machined aluminium with a unique carbon fibre-reinforced composite in an injection moulded oil control valve within the variable valve timing system that controls engine intake and exhaust. The high-performance thermoplastic valve (2-8 valves per vehicle depending on engine size) reduces cost and weight and improves engine response time, hence engine performance. Called Sumiploy™ CS5530 resin, the polymer is produced by Sumitomo Chemical in Tokyo. Sumiploy resin is a unique formulation of Sumitomo’s SumikaExcel™ polyethersulfone (PES) resin plus chopped carbon fibre and a proprietary additive package that boosts wear resistance and dimensional stability. The resulting highperformance composite offers excellent thermal resistance, good dimensional stability and long-term creep resistance over a broad temperature range, good impact strength, chemical resistance to aromatic hydrocarbons like gasoline, ethanol, and engine oil, inherent flame retardance,

and high environmental stresscrack resistance (ESCR). Unlike many other high-temperature thermoplastics that are challenging to mould, Sumiploy CS5530 resin is high-flow, making it easier to molud high-precision 3D geometries in thin walls. For the oil control valve application, key engineering requirements that Sumiploy CS5530 composite had to pass include ultra-high dimensional accuracy (10.7mm ± 50μm or 0.5%), thermal stability from -40 to 150C, low coefficient of friction, chemical resistance to engine oils, and excellent fatigue strength and creep resistance. Drivers for making the change from machined aluminium to an engineering thermoplastic composite include lowering manufacturing costs, improving engine performance, and lowering weight. The part has been in commercial use since start-of-production (SOP) in 2015, thus establishing a proven record of performance. Being a thermoplastic, it is fully recyclable (melt reprocessable) at the end of vehicle life.

An Asian automaker has replaced machined aluminium (upper left) with a unique carbon fibre-reinforced composite (lower right) in an injection moulded oil control valve within the variable valve timing system that controls engine intake and exhaust

AROUND THE WORLD Ravago buys California distributor RAVAGO Americas has acquired resin distributor Bolcof-Port Polymers of Azusa, California, its second deal of September this year and 10th overall since 2016. Bolcof-Port will become part of Ravago’s Amco Polymers unit. Bolcof-Port has been in operation since the 1960s and was one of the first resin distributors in southern California. “We continue to make strategic acquisitions that add to the strength of our distribution companies,” Ravago Holdings Americas CEO Jim Duffy said. “Bolcof’s portfolio, market understanding and reputation, especially on the West Coast, will both complement and strengthen the Amco business.” The deal includes a facility in Azusa that will provide Amco with additional on-site rail storage/ access, local warehousing, packaging and van/bulk truck delivery capabilities. Florida-based Ravago Americas has also acquired I Stern & Co, a distributor and reseller of commodity resins based in New Jersey (east coast of USA). • Ravago is the owner of Plastomark and Ultra Polymers in South Africa.

Indorama, Loop of Canada in rPET venture INDORAMA Ventures Public and Canadian recycling technology startup Loop Industries Inc have joined forces to create a PET and polyester recycling venture to address growing demand for sustainable plastics. The joint venture will seek to manufacture and commercialize ‘100% sustainable and recycled PET resin and polyester fibre’ using Loop’s depolymerization technology,’ the Thai chemicals giant announced on 24 September. The 50:50 joint venture will be retrofitted to one of Indorama’s existing plants on the US East Coast. Loop’s technology breaks down plastic molecules to basic monomers DMT and MEG which can then be put back together to produce PET. The PET, according to the spokesman, has been FDAapproved for food contact standards and will be supplied to beverage and consumer packaged goods industries. The production facility is set to begin commercial operation in the first quarter of 2020.

74 DECEMBER 2018 / JANUARY 2019

Piovan to list on Milan bourse ITALIAN auxiliary equipment manufacturer Piovan SpA plans to go public in the Milan stock exchange, Borsa Italiana, by the end of the year. The shares, expected to amount to 35-40% of the company’s capital, will be sold through a private placement for investors in Italy and institutional investors abroad. Pentafin SpA, Piovan’s controlling shareholder, will offer the shares. Piovan, an international auxiliary equipment maker for the plastics industry, had sales of €213-million euros (R3,6-billion) in 2017. The company has since 2015 become increasingly active in equipment for food powders. www.sumikamaterials.com


Rapid Granulator ad '017 10-BLEED.indd 86

2018/07/04 11:45


World News

Machinery for innovative woven plastic packaging Starlinger Open House in Taicang

coated or laminated and converted into sacks. At Chinaplas, Starlinger exhibited the RX 6.0 for a lightweight fabric with a working width of 300 – 850 mm double flat; at the open house, the models RX 6.1 (for 850 – 1300 mm) and RX 8.0 II for high-performance fabric were shown in operation. High-performance fabric is mainly used for applications such as FIBCs, tarpaulins, geo- and agrotextiles. The open house also featured live demonstrations of the coating line lamiTEC LX – including a fully automatic roll change at production speed – and the conversion line ad*starKON, which turns fabric into the well-known AD*STAR block bottom valve sacks for free-flowing bulk goods such as cement or fertilizer. Optionally, a

North American plastics machinery shipments up

After a strong Q1 Y/Y in 2018 shipment, Q2 moderated on a quarterly basis. “Plastics machinery shipments seemed to have hit a speed bump in the second quarter, but there’s no indication that shipments for the remainder of the year are trending down,” said Perc Pineda, chief economist at CES. The shipments value of injection moulding rose 4.5% in Q2 compared to last year. The shipments value of singlescrew extruders increased 23.1% from the previous quarter. The shipments value of twin-screw extruders – which includes both co-rotating and counter-rotating machines – increased 80 percent. “We can expect to see continued uneven quarterly data moving forward, but by and large the outlook for plastics machinery remains positive,” Pineda added.

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DURING Chinaplas in April, Starlinger welcomed more than 600 international visitors, and about 200 guests also attended the company’s open house in Taicang. The machinery demonstrations were met with great interest: high-tech weaving on circular looms type RX, consistently high coating quality and roll change at production speed on the lamiTEC LX, and precise sack conversion on the ad*starKON. The Starlinger factory in Taicang near Shanghai was founded in 2005 to satisfy the growing demand of the Asian market. In addition to serving regional customers, the factory produces a wide range of circular looms on site. These circular looms weave plastic tapes into the fabric that is then

PLASTICS machinery shipments in North America continued to increase in the second quarter of 2018 according to statistics compiled by the Plastics Industry Association’s Committee on Equipment Statistics (CES). This is the fifth consecutive quarterly year-over-year (Y/Y) increase. The preliminary estimate of shipments of primary plastics equipment (injection moulding and extrusion machines) for reporting companies totaled $335,2-million in the second quarter of 2018. This was a moderate increase of 1.6 percent from the $329,8-million revised figure in the previous quarter, but a 5.9% increase from Q2 of 2017.

Starlinger Open House at Starlinger Plastics Machinery in Taicang

micro perforation unit creates tiny holes for efficient aeration of the sacks. During filling, these holes allow the excess air to escape, while the content stays safely inside the sack. Today, more than 10 billion AD*STAR sacks are produced on Starlinger lines in more than 150 production plants every year. Visitors to the open house were mostly from Southeast Asia, Asia, Africa, the Middle East, and South America. Already during the fair, companies invested in machinery for new sack projects, for a capacity extension, or for replacement of existing equipment. At the factory in Taicang, Starlinger offers comprehensive technical training, machinery demonstrations as well as product tests for customers.

RPC in buyout talks with US private equity firms LEADING UK plastics packaging firm RPC Group plc, with global operations including more than 20 plants in North America, is in preliminary discussions with US-based private equity firms Apollo Global Management and Bain Capital over two possible buyout offers. The RPC statement came in response to a Bloomberg report saying the leading European packaging firm was in talks with potential buyers. The report valued the company at £2.8 billion ($3.6 billion), noting a 20% decline in RPC’s shares this year. RPC reported a 36.4% year-on-year increase in sales at £3.74 billion ($4.8 billion) for the full year in 2017, with adjusted profit before tax up 36.1% at £389 million ($506.9 million).


Compostable crisp bag lights up Packaging Innovations 2018 Higher barrier materials, metallisation techniques key to package COMPOSTABLE and renewable packaging film specialists, Futamura, grabbed headlines at Packaging Innovations 2018 in London recently with its 100% plasticfree, compostable crisp bag made from barrier film NatureFlex. The bag is the first of its kind on the European market, originally launched in Germany. Futamura collaborated with packaging manufacturer Bio4Pack to create the pack for German organic crisps producer, myCHIPSBOX. PackagingInsights sat down with Andy Sweetman, UK Marketing Manager at Futamura, during the show to discuss the stand-out innovation. “To make a product which is as sensitive to moisture and light as crisps and package it in non-plastic materials is a real technical challenge,” explains Sweetman. “What we have here is a laminate of two different materials: NatureFlex on the outside providing the barrier properties, laminated to another material on the inside which is giving perfect seal integrity.” “So although we are using two different materials, what they have in common is that they are both compostable, providing an option for end-of-life reuse of the material through composting, whereas otherwise conventional plastics will not be recyclable.” Beyond crisps, the pack can also be used for other foods. Sweetman continues: “The bag can be used for any kind of

dry foods. All different food products have different technical needs but with NaturaFlex material, we can actually modify the barrier properties depending on the specific needs of those food products.” “For example, we can package for cheeses or baked goods which might need some permeability. With foods like potato chips, cookies biscuits and so on, that’s where we deliberately make the materials very much more barrier proof to moisture.” Sweetman describes how this product is the first of its kind on the European market, but that the concept can go much wider: “We can go pretty much worldwide,” he says. “Certainly in the Americas there are a lot of packs using similar types of constructions already for potato chips.” “Two or three years ago, this type of pack wasn’t possible. It’s the introduction of higher barrier materials from us and metallization techniques which allow us to achieve these kind of properties, so it’s very much a development of the last two or three years,” Sweetman concludes. The supplier’s bio-films are manufactured using renewable resources, predominately wood-pulp from managed plantation) and are certified to the European (EN13432) and American (ASTM D6400) norms for industrially compostable packaging.

CAE used to forecast part deformation during LCP part production POLYPLASTICS, a leading global supplier of engineering thermoplastics, is successfully using computeraided engineering (CAE) analysis to forecast part deformation during the reflow process when manufacturing connector parts are made of liquid crystal polymer (LCP). These LCP connectors are finding growing use in mobile devices such as smartphones and switches, along with automotiverelated applications. The project looks at how deformation of LCPs such as its Laperos® resin can be minimised during the reflow soldering process used in the production of circuit boards or other electronic wiring mouldings. In the process, a solder paste is used to temporarily attach one or several electrical components to their contact pads, after which the entire assembly is subjected to controlled heat, which melts the solder, permanently connecting the joint. Heating may be accomplished by passing the assembly through a reflow oven or under an infrared lamp or by soldering individual joints with a hot air pencil, so it is important for Polyplastics’ materials to deform by as little as possible during the process.

Andy Sweetman, UK Marketing Manager at Futamura

www.polyplastics.com

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Diary 665 EXHIBITORS AT 12TH ISSUE OF IRANPLAST

COMING UP

THE 12th edition of the IranPlast international exhibition attracted a relatively large number of non-Iranian firms to the show in Tehran in September. The exhibition’s inauguration ceremony was much cooler than the other previous years, due apparently to the absence of President Rouhani’s first deputy, the Oil Minister. Bijan Namdar Zangeneh and his accompanying delegation. Motivated as ‘the Boom in the global business of plastic industry,’ the show involved 665 Iranian and foreign exhibitors, with 35 countries represented. With the effect of the sanctions on Iran applied by the United States, the show was seen partly as an opportunity for Iranian petrochemical businesses to enhance exports, and a record number of exhibitors and participants was expected this year.

Soft skin adhesive – Dow Silicones and DuPont, subsidiaries of the Specialty Products Division of DowDuPont, launched a new, high-performance soft skin adhesive at Compamed 2018 in Düsseldorf in November. Dow Silicones showcased its Dow Corning™ brand medical silicones, which encompass silicone elastomers, solutions for siliconization and device adhesion and liquid silicone rubber. Featured among these, Dow Silicones’ new soft skin adhesive offers extended wear properties for skin-adhered medical devices

FIRE RESISTANCE IN PLASTICS THE 13th edition of AMI’s international Fire Resistance in Plastics Conference will take place on 10-12 December at the Maritim Hotel in Cologne, Germany. Increasingly stringent fire, health and environmental protection regulation is driving the need for safer and more efficient flame retardant systems in electrical and electronic goods, construction and transportation. This December, a panel of expert speakers will deliver papers discussing the state of the art in flame retardant plastics, as well as the latest developments in markets, technology, materials, testing and regulation. Fire Resistance in Plastics 2018 boasts a broad international audience with companies joining from all around the world. It brings together representatives of the entire supply chain (from raw material suppliers to users), offering unrivalled opportunities to network, exchange experience and learn through interaction with colleagues, suppliers, customers and competitor. www.ami.international

Celebrating success at THE Electra Mining Africa event remains one of the most popular industry exhibitions in South Africa, with the 2018 edition of the event featuring over 600 exhibitors from 59 countries and attracting over 21 000 industry ‘decision-makers’. The show, at the Nasrec Expo Centre in Johannesburg, was an action-packed expo showcasing an exciting range of new products, innovations, interactive demonstrations and professional expertise. Presented by the well-known

Specialised Exhibitions/Montgomery (also the host of Propak Africa due in March), the show created the opportunity for the many potential buyers to view leading products, specialised services and cuttingedge machinery, equipment and solutions. “All enabling effective business growth, more streamlined operations and ensuring a business that remains future-fit,” Specialised send in a postshow summary. • Electra Mining Africa will next be held in September 2020.

Blast it! – Jon Meyer, Jannie van der Linde, Jeremy Faria and Lourens Potgieter from the Dry Ice Blasting team. Dry ice blasting is similar to sand blasting and ideal for cleaning paint, glue, dirt and grease from urethane and plastic moulds with no damage to the surface

You just have to dig Event explores the essential need for trenchless technology – it’s the future of infrastructure installation TO THE uninformed it might have appeared that No Dig South Africa 2018 may have been a cultish movement on a Burning Man scale, but on closer examination it became apparent that it was International Society for Trenchless Technology’s 36th annual conference and exhibition. Presented in South Africa this year, by the South African STT, the event took place at the Cape Town International Convention Centre on 8/9 October. The show created a unique opportunity for suppliers to showcase products and services at the only event on the African continent to focus on trenchless technology. With the great need in South Africa for the renovation of ageing underground services, there is little doubt that on-going work is required (if only more of the municipal authorities would become more proactive and invest in maintenance and upgrading). There was a gala banquet on first night of No-Dig Africa which drew over 200 Gabriel Reddy of Inkulu of KZN was at the gala event at the Bay Hotel in Camps Bay with colleagues Reggie Cutting, who runs Inkulu’s Cape operation, and Darren Reddy, who manages logistics for the Cape supply route from the Hammarsdale plant

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Electra Mining Africa Aussie connection – Era Polymers Africa hosted a visit by a representative of their Australian head office, Martin Morrisey (left back) of Sydney. Here we see him with Alf and Liz DeVincentiis and Gerhard Cronje of Johannesburg-based Era. Morrissey was at Electra Mining to support the team. Era Polymers is a family-owned polyurethane systems house founded in1986 by George and Tina Papamanuel in Sydney. In South Africa, the company manufactures PU systems for elastomers, foams spray systems, membranes and coatings from a state-of-the-art production facility in Founders View, Johannesburg

Toplica Stojanovic of Eltim Engineering, a supplier of a range of adhesives, and Beatrice Goetze of Perspex South Africa on the Perspex stand. Beatrice is holding a sample of Perspex’s latest high-abrasion resistant durable LinaShield sheet. Linashield, which is manufactured locally, is suited for lining applications where, besides it resistance to abrasion, it is also resistant to oils, greases and many solvents and fats

www.electramining.co.za

No Dig Africa banquetees from all over the country and further afield for an entertaining programme featuring local musicians, minstrals and the like.

New in the pipe line – Borealis SA/Borouge presented its new BorSafe™ PE 100 pipe material at No-Dig Africa in October. Here we see Chris Joubert of IMCD, Andrew Pienaar of Borealis Chemicals ZA, Quentin van Rensburg of IMCD and Sultan Al Kendi of Borouge PTE of Abu Dhabi, UAE with samples of moulded product. BorSafe™ HE 3490-LS-H is a new black, bimodal HDPE classified as as an MRS 10.0 material produced by the advanced Borstar® technology. Long-term stability is ensured by an optimised stabilization system

Composite products for the entire spectrum at CAMX 2018 THE entire composites spectrum is COBRA Internationals’ focus at CAMX this year with the company showcasing a range of composite products that span its full offering including carbon fibre components for the automotive, transportation, marine, water sports and luxury sectors. CAMX took place in Dallas, Texas from 15-18 October. From the CAC (COBRA Advanced Composites) team, now a crucial partner to many world-class premium automotive and motorcycle manufacturers in Germany, Italy, Japan and the UK, parts on display for the transportation sector include examples of ultra-lightweight motorbike fairings and suspension arms. A full carbon sports car wheel which was designed, built and engineered at COBRA’s multi-million dollar automotive manufacturing and finishing plant in Chonburi will also be on the booth. Representing the work of the design and development department, COBRA’s internal hot house for new product development, a new carbon chaise prototype was also be on display having been built in partnership with customer Sutherland Furniture. One of two prototypes, COBRA’s D&D team led the cooperation in terms of design, material sourcing, engineering and production to create a new modern take on the traditional chaise seat design that combines a full carbon structure with a waterproof textile net that is also created by COBRA.

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Varied solutions for the waste world at Wastecon WASTECON 2018 was held at Emperors in Johannesburg and attracted participation by a variety of plastics suppliers, including size-reduction specialist Zerma Africa, returnable transit packaging containers manufacturer Mpct Plastic Containers and recycler Tufflex, all of who engaged with state and regional government personnel and in fact all those involved in the waste management business.

Chantal Shaw and Jeff Cawcutt of Zerma Africa flank visitor Ina-Mari Janse van Rensburg of Jobe Environmental Systems (previously Otto SA). On this occasion Zerma did not exhibit any equipment, but there can be no doubt that size reduction is at the core of the waste management business

www.tufflex.co.za Charles Muller and Tanya Owens of Tufflex (standing) hosted visitors Dr Margaret Molefe of the Department of Environmental Affairs and Zingisa Smale of the Gauteng Department of Agriculture & Rural Development on their stand. Tufflex is now is now yielding advantages of consistently higher quality processed material resulting from its large-scale Herbold wash plant installed late in 2017. At Wastecon Tufflex showed off examples of its recycled ‘plastic timber,’ with the new white profiles proving eye-catching

www.mpcsa.co.za Making an Mpact – The Mpact Plastic Containers team exhibited a range of its waste management containers, some of which are manufactured in recycled material. MPC has become a local leader in workplace and public space recycling solutions as well as in the returnable transit packaging (RTP), meaning that many of these containers have extended life spans

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Major hall expansion at K organiser Messe Düsseldorf MESSE Düsseldorf has reached the halfway point in one of the most ambitious construction projects in its history, the topping-out ceremony for the new Hall 1. Comprising the new Hall 1 and the state-of-the-art south entrance, this complex will strengthen Messe Düsseldorf as an international meeting point for industry. The project, which will be completed by third quarter 2019, includes the new multifunctional Hall 1 with meeting rooms, the glass-enclosed new south entrance with a translucent illuminated canopy and an adjacent underground car park. Hall 1 will be 12 027m² in size, offering space for up to 10 000 people. The first floor will also have six glass-enclosed meeting rooms, each with 200m² and space for 198 people. One of these rooms will protrude into the foyer of the new south entrance, which will provide 2 112m² of event space. In front of it, 20m

high and covering 7 800m², there will be a canopy over a plaza with taxi ranks, public transport connections and an entrance to the new underground car park. This forecourt will also be suitable for events. The traditional topping-out speech was given by the construction managers, Thomas Schulte and Holger Meyer of Osnabrücker Köster GmbH, at the building site on 14 September

www.k-online.com

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COMING UP

WIND TURBINE EVENT IN DÜSSELDORF IN DECEMBER THE wind turbine blade industry continues to change as it grows. Top manufacturers and turbine makers will be discussing and presenting their latest developments at the 9th annual conference on Wind Turbine Blade Manufacture which will take place from 10-12 December at the Maritim Hotel in Düsseldorf, Germany. The conference will kick off as usual with a market analysis by Cristina de Santos, Energy & Infrastructure Unit Manager with AMI Consulting. This year, the presentation will summarise the main conclusions of AMI Consulting’s 2018 research on the industry. China continues to be the largest blade manufacturing country in the world, with market leader Sinoma Wind Power Blade accounting for over 7% of global blade production in 2017. AMI is honoured to host Sinoma as it delivers its first presentation at a European event on the key challenges facing Chinese blade suppliers. Innogy, one of Germany’s leading energy companies, will also provide delegates with an overview of rotor blade requirements from an operator’s point of view.

THERMOPLASTIC CONCENTRATES IN FLORIDA, USA APPLIED Market Information recently launched the programme for its annual Thermoplastic Concentrates 2019, the twenty second in this series of high-level business conferences that takes place from 29-31 January in Coral Springs, Florida. The event is the forum where leaders in the industry meet to discuss innovations and business developments. Attendance accounts for over 90% of the industry by value and volume (over $3,3-billion) with almost every major producer represented. This annual event consistently delivers quality papers which not only deal with the unpredictable turns of the economy, but gives real business insight into the successful management of companies. Papers to be presented will cover a detailed review on the future direction of the market and customer demand, colour trends, raw material innovations and technical developments. The conclusion of the conference will also address topics regarding staff retention, future industry structure and raw material availability and pricing trends. www.ami.international

Coca-Cola

host site tour of Mpact Polymers

THE Coca-Cola Company in South Africa recently hosted a site tour of the Mpact Polymers recycling plant in Wadeville, followed by a tour of the biggest bottling plant, owned by Coca-Cola Beverages South Africa (CCBSA). The half day tour took members of the media on a Coca-Cola plastic bottle journey, demonstrating a plastic bottle’s lifecycle to better understand the recycling ecosystem and the manufacturing process. Mpact Polymers’ R350-million state-ofthe-art recycling bottle-to-bottle facility is

Mpact Polymers’ recycling plant in Wadeville where the baling of recycled bottles takes place

the first of its kind in Africa. The recycled PET gets transported to CCBSA where preforms are blown into PET bottles and subsequently filled. Currently CCBSA PET bottles have between 10-15% recycled content with the plant able to run up to 25% recycled content. Durandt mentioned Coca-Cola intended to stop production of all coloured PET i.e. Stoney and Sprite bottles. He also spoke about manufacturing a one-piece bottle with the closure developed to be permanently attached.

Dr Casper Durandt, franchise technical director at CocaCola Southern Africa (standing on the right) addresses members of the media about CocaCola and Mpact Polymers’ endeavours in packaging sustainability for ‘A World without Waste’

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Fine mesh straining of rubber compound Innovative gear pump technology ensures high level of quality improvement, cost-savings INNOVATIVE technologies for processing of rubber compound will be the focus at the India Rubber Expo 2019, from 17–19 January in Mumbai, at the Bombay Exhibition Centre. UTH GmbH from Fulda, Germany, will be presenting its latest range of products. This

www.UTH-gmbh.com

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Roll-ex® 220 TRF – Fine mesh staining of rubber compound yields a throughput of up to 2500kg/h

DEC 2018 / Jan 2019

includes both roll-ex® fine mesh straining systems and roll-ex® gear pump technology. With a focus on its unique gear pump technology for rubber extrusion and fine mesh straining technology, UTH GmbH will present its solutions for applications requiring a high level of product quality, cost-efficiency and material-saving. The processing of rubber compounds continously presents the rubber industry with new challenges and tasks. The market demands highly cost-effective products of the highest quality. Accordingly, UTH has focussed on perfecting the manufacturing of rubber and silicone products. With throughputs up to 10 000kg/h UTH’s roll-ex® gear extruder systems have set the benchmark worldwide for fine mesh straining of rubber compounds. Using either the compact two-roll feeder (TRF) or a conical twin screw feeder (DSE), the modular design of the roll-ex system enables the integration of the strainer in each specific line design. Because of the flexible and compact design a seemless integration into existing lines is also possible. Precise and gentle extrusion is another main feature of roll-ex gear extruders and gear pumps which have high working pressures of up to 800 bar. UTH can supply complete lines as a system solution for the manufacture of rubber-coated wire, yarn or fibre components.

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Diary POLYETHYLENE FILMS 2019, ALSO IN FLORIDA

COMING UP

THE programme for Polyethylene Films 2019, also run by Applied Market Information, is available. This wellestablished business conference for the polyethylene film industry takes place from 5-7 February in Coral Springs Florida, United States. The event will be sponsored by M Holland as the headline sponsor with additional support from ExxonMobil, Clariant, Ampacet and Techmer PM. Polyethylene Films is a 3-day event looking at both the business challenges and technical developments of polyethylene films and brings together the thought leaders and senior managers within the industry. Attendance typically represents about over three million tons p/a of film production within the North American market. Presentations from Dow Chemical, Nova Chemicals, LyondellBasell, Polyplastics USA, Celanese, Mitsui Plastics, Ingenia Polymers, A Schulman, Techmer PM, Clariant, Davis-Standard, Kuhne, Aquatech, Nova Chemicals, Reifenhäuser, Novolex, Mesirow Financial and Wood Mackenzie are scheduled. www.ami.international/events

AFRICA ENERGY INDABA THE Africa Energy Indaba conference/ exhibition on 19-20 February 2019 takes place in the Sandton Convention Centre, Johannesburg. The conference will discuss, debate and seek solutions to enable adequate energy generation across the continent. Delegates, drawn from all continents, represent an unrivalled combination of industry experts, project developers, financiers, energy users, government officials and manufacturers. The conference also provides with the exciting side events listed below: • Africa Gas Forum • IPP & PPA Conference • Women in Energy Conference • SANEA Energy dialogue www.africaenergyindaba.com

USA’S ANTEC IN DETROIT IN MARCH ANTEC, reported to be the largest international technical meeting of individuals representing industry, government and academia providing a broad perspective on the science, engineering and business of plastics, takes place in Detroit, Michigan, from 18-21 March 2019. The event covers the entire spectrum of plastics processing technologies, from additive manufacturing to thermosets. ANTEC boasts 550+ technical and business papers on new and updated technologies, 60+ marketing presentations, two days of packaging, building & construction and transportation ‘megatrends’ sessions, panels and tutorials, networking events and student functions-all providing attendees with face-to-face interaction with expert representatives from the largest industry segments. 84 DEC 2018 / Jan 2019

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Fakuma 2018

BASF showcases Showing off their latest innovations and boundary breakings AT this year’s Fakuma in Friedrichshafen, Germany, BASF showcased their latest developments in the automotive, lifestyle and industrial development sectors. Ultramid Deep Gloss now in colour The development of the specialty polyamide Ultramid Deep Gloss continues to make progress. After having been successfully launched on the market and winning the German Innovation Award, the product now turns from black to colourful. The excellent property profile remains unchanged: resistance to scratching, high chemical and good UV resistance. In addition, the high gloss level reproduces structures with faithful detail, allowing a highly contrasting mix of light and shadow – without additional coating. Multi-talented Infinergy scores well in the sports sector In 2013, Infinergy (E-TPU) was launched in the adidas Energy Boost shoe. Today, Infinergy is also popular in other sports applications. The material was exhibited not only in the adidas shoes but in

applications such as bicycle saddles, bicycle tires, treadmills and other sports equipment. The closed-cell particle foam’s property makes it suitable for a variety of sports applications. It provides both cushioning and spring and is therefore ideal for sports that put intense stress on joints. The high rebound effect is achieved by the special air cell structure made from welded foam beads. Seating at stand provided by lightweight Aula from Wilkhahn Aula is the name of the latest chair model from Wilkhahn. The fully plastic frame and the armrests are made from Ultramid SI, the surface-optimised plastic from BASF. With this chair, designers and engineers have taken plastic to new esthetic and functional dimensions. BASF’s simulation capabilities (Ultrasim®) also played a key part in ensuring that every part of the chair frame could be produced from a high-performance plastic (Ultramid SI), making rendering a steel core unnecessary. This resulted in a new

PC protects the heart of electric mobility THE Alta Pack battery of Californiabased electric bike specialist Alta Motors is equipped with a jacket made of the extremely impact-resistant PC-PBT blend Makroblend from Covestro. At the Fakuma 2018 trade fair, Covestro presented various battery modules, cell holders, crash absorbers and other products at its stand. One of Covestro’s current focal points is the use of polycarbonate plastics in electric vehicles. Covestro has many years of experience in encapsulating lithium-ion batteries for laptops and other electronic devices. To achieve this, the company has developed various polycarbonate blends that meet these requirements and are also extremely impact-resistant over a wide temperature range – especially at sub-zero temperatures. A flameretardant polycarbonate ABS blend of the Bayblend FR type is ideal for cell holders and battery modules. It is temperatureresistant and dimensionally stable and the parts can be produced efficiently with injection moulding.

www.covestro.com

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Fakuma 2018

variety of new products at Fakuma weight class. At only 6kg or 6.7kg in the design with armrests, the Aula is lightweight. Ultramid Flex for soft packaging Ultramid Flex F38 is the new bio-based copolyamide from BASF. Due to its outstanding properties even at low temperatures and low humidity it is ideally suited for soft packaging, as well as a wide array of technical ďŹ lms. Beyond its technical performance, Ultramid Flex F38 provides a distinct contribution to sustainability, as parts of the raw materials are sourced from locally grown rapeseed oil. For the packaging industry, the new Ultramid Flex F unlocks entirely new opportunities for launching bio-based products onto the market.

www.moretto.com

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CONTACT

LES PORTER Cell: +27 83 255 9865 Tel: +27 11 762 5231 E-mail: spark@mweb.co.za Diary new.indd 85

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Diary COMPOUNDING WORLD EXPO IN USA IN 2019 AMI is to present its Compounding World Expo in the United States next year. The free-to-attend exhibitions Compounding World Expo, Extrusion Expo and Plastics Recycling World Expo will be held at the Huntington Convention Centre in downtown Cleveland, Ohio, on 8/9 May 2019. The events will follow on from AMI’s first Compounding World Expo and Plastics Recycling World Exhibition, which took place in Essen, Germany, in June and attracted widespread industry support.

COMING UP

SA MANUFACTURING SECTOR SET TO GROW IF RECENT investments in the manufacturing industry are indicative of the trend going forwards, then the future is looking bright for this often beleaguered market sector. In addition, the South African government recently announced that it was embarking on an offensive to attract $100-billion (approximately R1.3-trillion) in foreign direct investment (FDI) over the next five years to bolster the local economy. Charlene Hefer, portfolio director for Specialised Exhibitions Montgomery, says that a number of notable manufacturing plant projects have created a sense of hope for the country, including the R50-million Automotive Industry Centre (AIDC) mega-development in Rosslyn near Pretoria. Fuchs Lubricants South Africa also recently opened its R125-million grease plant expansion in Isando and Russian rolling stock manufacturer Transmasholding (TMH) launched a R500-million investment in a South African manufacturing facility through its subsidiary TMH Africa. Not only does the manufacturing industry in the country provide income and job opportunities to those people directly employed in the sector, but it also has high economic multipliers in its linkages to upstream production sectors (mining and agriculture) and downstream sectors, including services. Recognising the importance of promoting local manufacturing to other countries, Specialised Exhibitions Montgomery, in association with the South African Capital Equipment Export Council (SACEEC), is launching the Local Southern African Manufacturing Expo (LME) in Johannesburg from 21-23 May 2019. To book a stand at LME 2019 or to find out more information about the exhibition visit the website.

Fakuma 2018

TPEs for decorated surfaces Kraiburg TPE presented a new thermoplastic elastomers series at Fakuma, especially developed for decorated surfaces that appeal to the touch and for functional parts inside motor vehicle cabins. Thanks to their superior processing behaviour, the new lowemission and low-odour FG/FS Thermoplast® K compounds can be processed at relatively low pressures and precisely reproduce the surfaces of even geometrically complex components. They are available in the standard colours, black and natural, as well as in OEMspecific colours and also allow individual colouring. Applications range from complex, durable floor mats and antislip mats to panels and decorative surfaces to thumb wheels, switches, and handles

Polyplastics focus on e-mobility POLYPLASTICS focused on e-mobility, along with its efforts in research and development at Fakuma 2018 in Germany. Polyplastics exhibited their latest developments in its broad product portfolio including Duracon POM, Duranex PBT, Durafide PPS, Laperos LCP and Topas COC resins, as well as examples of recent applications in new energy vehicles, highend electric devices and food and sanitary will also be displayed.

Other key material developments include POM resin grades with lowVOC emissions for the production of automotive interiors. These Duracon low-VOC acetal grades are specifically designed to meet the latest regulations governing the concentration of VOCs in automotive interiors. Polyplastics also highlighted its new Durafide PPS grade which delivers an improved heat shock resistance for a range of automotive applications. Additionally, the company showcased its extensive range of engineering thermoplastics which facilitate laser welding of housing components for the automotive and electrical/electronic industries. www.polyplastics.com

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Fakuma 2018

New ‘Imflux’ injection technology shown on Milacron machine Uses constant, low pressure to slowly fill mould while simultaneously packing melt and cooling mould INJECTION moulding technology from Imflux, part of brands group Procter & Gamble Co, was exhibited on a Milacron machine at Fakuma in October. A technical part was manufactured on an all-electric Elektron EVO 155 machine running a four-cavity Imflux mould. “It’s a seamless integration of Imflux in a moulding machine,” said Gene Altonen, Imflux chief technology officer. The injection machine was equipped with Imflux software and pressure sensors inside the mould and nozzle. Imflux uses constant, low pressure to slowly fill the mould while simultaneously packing the melt and cooling the mould. Imflux software, linked to sensors, controls the process. Traditional injection moulding uses high pressure and high temperatures, then switches over to the pack-and-hold phase. Imflux officials say the technology can cut cycle time, reduce moulding pressure by 50%, reduce moulded-in stress and shrink variations and allow a wider range of processing windows and shrink variations inside the mould, among other benefits. The Fakuma demonstration is designed to show off Imflux’s capabilities, such as Auto Viscosity Adjust, which automatically makes adjustments for variations on viscosity. Altonen said the four-cavity mould was “intentionally unbalanced”. And the injection machine changed materials and colours during moulding, from white HDPE to red PP and back. www.imflux.com

Ethan Stiefel, left, and Brandon Birchmeier from Imflux at Fakuma 2018 DEC 2018 / Jan 2019

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Untitled-2 1 Diary new.indd 87

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2018/09/14 2018/11/19 11:41 16:34


Fakuma 2018

Diary

COMING UP

CHINAPLAS IN MAY CHINAPLAS 2019, currently the world’s leading plastics and rubber trade fair, will be held from 21-24 May 2019 at the China Import and Export Fair Complex, Pazhou, Guangzhou, PR China. It is expected that more than 3,400 exhibitors from around the world together with 13 country pavilions will take part in the event and display more than 3,800 sets of machinery, providing solutions to various user industries such as packaging, automotive, E&E, IT, telecommunications, building & construction and medical. The fairground will cover a total exhibition area of 250,000m² First introduced in 1983, Chinaplas has been approved by UFI (The Global Association of the Exhibition Industry) since 2006. It is exclusively sponsored by the Europe’s Association for Plastics and Rubber Machinery Manufacturers (EUROMAP) in China for the 30th time. www.africaenergyindaba.com

FDT AFRICA IN JULY FOOD & Drink Technology Africa 2019, to take place in Johannesburg from 9-11 July 2019, will co-locate with the premiere trade fairs analytica Lab Africa and IFAT Africa (trade fair for water, sewage, refuse and recycling). fdt Africa’s platform is becoming one of the most important networking and business platforms for the beverage and food industry in South Africa, designed especially for the needs of the Southern African market. It gives you a comprehensive overview of the latest developments in the beverage and food industry. The co-locating events will showcase new innovations in the areas of analysis as well as beverage, food and environmental technologies at one venue, namely the Gallagher Convention Centre.

High-performance IML High speed and process reliability boost added value with in-mould labelling

BECK Automation presented at Fakuma 2018 a compact, high-performance IML automation system for yoghurt tubs with a full wrap label. The trade fair exhibit is characterised by high speed, process stability and very high availability with short cycle times. The exact interaction of the individual components comprising the automation system, the injection moulding machine, the mould, label quality and optical quality controls increase productivity and added value. On an Elexis SP 200-920 injection

Lanxess conducts flame retardancy tests in compliance with standards on test specimens and components – for example, glow wire tests

2018 PU Tech Africa Sandton Convention Centre PETnology Europe 2018 Paris, France

88 DEC 2018 / Jan 2019

Valve World Expo Düsseldorf, Germany

20-21 November expo@technobiz-asia.com 26-27 November www.petnology.com 27-29 November www.valveworldexpo.de

LANXESS expands

Polyethylene Films Coral Springs, Florida

5-7 February www.ami.international/events

Africa Energy Indaba Sandton Convention Centre

19-20 February www.africaenergyindaba.com

Propak Africa Expo Centre Nasrec, Johannesburg

12-15 March www.propakafrica.co.za

ANTEC 2019 Detroit, MI, USA

18-21 March www.4SPE.org/ANTEC

Fire Resistance in Plastics Maritim Hotel, Cologne, Germany

10-12 December www.ami.international/events

Plástico Brasil São Paulo, Brazil

Wind Turbine Blade Manufacture Maritim Hotel Düsseldorf, Germany

10-12 December www.ami.international/events

IOM National Rubber Conference Cape St Francis Resort Compounding World Expo Cleveland, Ohio, USA

2019 India Rubber Expo 2019 Bombay Exhibition Centre, Mumbai Thermoplastic Concentrates Coral Springs, Florida, USA

Diary new.indd 88

moulding machine from Sumitomo (SHI) Demag Plastics Machinery GmbH, yoghurt tubs are produced with a full wrap label on a high-performance IML automation system made by Beck; the total cycle time is less than 2.5 seconds. The system is equipped with a Vision System for optical quality control by Intravis GmbH. The heart of the Vision System is the IML Watcher, which features several cameras and specific lighting units depending on requirements. As a result, it is possible to detect the slightest errors

17-19 January www.UTH-gmbh.com 29-31 January www.ami.international/events

Local SA Manufacturing Expo Expo Centre, Nasrec, Johanensburg Chinaplas Pazhou, Guangzhou, PR China

25-29 March www.plasticobrasil.com.br 4-7 April iomsa@mweb.co.za 8-9 May www.compoundingworldexpo.com 21-23 May www.localmanufacturingexpo.co.za 21-24 May www.ChinaplasOnline.com

2018/11/19 16:35


Fakuma 2018

automation system for yoghurt tubs typical for the IML process, such as label presence, overflow and displacement or rotation of the label. The vision System is seamlessly integrated into the production line and supports the fastest cycle times of IML high-performance manufacturing. The use of lightweight materials on the main arm as well as high-performance linear motors enables rapid, dynamic movements. Two motors drive the main axle; this improves dynamic performance and extends the life of the belts and the engines.

The angled positioning of the label magazines, where the label is aligned with the print image facing downwards, minimises label warpage, which ensures optimal, precise positioning of the labels. Even with very fast cycle times, the labels are smoothly separated and transferred to the mandrels. The removal, transfer as well as the depositing and stacking of the products feature a truly impressive level of automation. www.beck-automation.com

range of PBT compounds Halogen-free and flame-retardant

www.lanxess.com

LANXESS is expanding its range of Halogen-free, flameretardant compounds based on polybutylene terephthalate (PBT) to include variants with outstanding fire resistance in glow wire tests. The first in the product range is a compound reinforced with a glass fibre content of 25%. There are plans to introduce the trial product onto the market shortly. The new PBT material has already been certified by VDE Prüf- und Zertifizierungsinstitut GmbH with a GWIT value of 775 °C for wall thicknesses of 0.4 to 3.0mm (Glow Wire Ignition Temperature, IEC 60695-2-13). It also achieves excellent results in glow wire tests on finished parts according to IEC 60695-2-11. Lanxess assume that it will also perform well in even stricter glow wire tests on the finished part for unattended household appliances according to IEC 60335-1 and can be used, for example, in components for washing machines, dishwashers, and tumble dryers. With these applications, the compound’s higher tracking resistance compared to flame-retardant materials containing halogen also pays off. The other properties of the new glow wire-resistant material are similar to those of other halogen-free, flame-retardant PBT compounds already on the market from Lanxess. These

Material innovations for

sustainable mobility from Lanxess PA 66 substitute – The cover of the tailgate handle system with integrated rear view camera is made from the non-reinforced PBT Pocan C1202LT. It is joined by laser transmission welding to the handle system housing made of Pocan B7425 in such a way that the locking electronics are sealed watertight.

include product variants reinforced with a glass fibre content of 13 to 30% and an unreinforced compound. They all achieve the best classification of V-0 in flammability testing pursuant to the United States’ UL 94 (Underwriter Laboratories Inc.) standard. They are also highly resistant to UV light and rarely corrode when in contact with live components. Another advantage is their high thermal stability. DEC 2018 / Jan 2019

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• Official Distributor in Southern Africa for BASF

on TPU Elastollan® Thermoplastic Polyurethane

• Official Distributor in Southern Africa for Elastron on TPE, TPV Elastron® SEBS and EPDM/PP

• Official Distributor in Southern Africa for CGFSE on FSE® Fluoroelastomers and Perfluoroelastomers

• Distributor for Weifang on Weipren CPE • Suppliers of EPS, Various Grades • Engineering Polymers • Polyolefins • Reworked and Repaletised Materials • Official distributor for Politem on PA6, PA66 ®

unfilled and filled compounds

www.lanxess.com

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2018/11/19 16:35


Books

Plastics recycling in Europe – a waste of time or a wasted opportunity? Recycling industry in Europe will need to more than double by 2030 to meet targets

ACCORDING to a recently published study by leading industry consultants Applied Market Information Ltd (AMI Consulting), the plastics recycling industry will have to develop and grow considerably to meet 2030 EU plastics packaging recycling targets, along with the effect of the Chinese waste import ban. PE recycling rates by Country 2017

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Global plastics manufacturing market expected to double in size Key players are AkzoNobel, BASF, Bayer, Borealis THE latest research study from HTF MI – Global Plastics Manufacturing by Manufacturers, Regions, Type and Application, Forecast to 2023 – includes a complete assessment of the market and future trends assessment. The publication includes current growth factors, attentive opinions, facts, and historical data and statistically supported and industry validated market data. The study is segmented by products type, application/endusers. The research study provides estimates for global plastics manufacturing forecast until 2023. The research covers the current and future market size of the global plastics manufacturing market and its growth rates based on five year history data. It also covers various types of segmentation such as by geography (North America, United States, Canada, Mexico, Asia-Pacific, China, India, Japan, South Korea, Australia, Indonesia, Singapore, Rest of AsiaPacific, Europe, Germany, France, UK, Italy, Spain, Russia, Rest of Europe, Central & South America, Brazil, Argentina, Rest of South America, Middle East & Africa, Saudi Arabia, Turkey & Rest of Middle East & Africa). Competition in the market is constantly increasing with the rise in technological innovation and M&A (merger and acquisitions) activities. Moreover, many local and regional vendors are offering specific application products for varied end-users. On the basis of attributes such as company overview, recent developments, strategies adopted by market leaders to ensure growth, sustainability, financial overview and recent developments. 90 DEC 2018 / Jan 2019

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The study expects that the current output capacity of the recycling industry in Europe will need to more than double by 2030 to meet targets. The challenge in growing capacity is that the plastics recycling industry is a complex, dynamic segment with a varied supply stream and value chain. With prices of recyclate intrinsically linked to the price of virgin resin, demand and the financial viability of the process is often subject to fluctuations in raw material prices. Due to this, demand for recyclate is increasingly coming down to brand owners desire to be seen as ‘environmentally friendly’ and ‘green’ and not down to financial incentives. This is primarily due to sustainability becoming increasingly more important to consumers, and plastic receiving considerable negative press bringing it to the forefront of many debates and discussions. AMI Consulting’s study, Plastics Recycling in Europe – capacities, capabilities and future trends published in June, gives an evaluation of current capacity in Europe and volumes of additional capacity required by 2030 by the following polymers PE, PP, PS, PET and PVC. The report delivers the current industry situation and forecasts where the industry will go in the future. Elizabeth.carroll@ami.international

IISRP publishes worldwide rubber statistics THE International Institute of Synthetic Rubber Producers (IISRP) has published the 2018 edition of Worldwide Rubber Statistics, the world’s leading source for authoritative data about synthetic rubber. This edition of the book, which has been published annually for more than 30 years, has revisions to elastomer plant capacities as the synthetic rubber market continues to be dynamic. Additionally, IISRP’s China office has played a key part in this publication to enhance intelligence on the Chinese market. The 85-page publication provides a comprehensive analysis of capacity by elastomer type, by geographical distribution and by corporate ownership. It also features a graphics section that emphasizes stats in easy-to-read format and a section on capacities of synthetic rubber production facilities throughout the world, including a section on planned and announced expansions of synthetic rubber plants. The book will be available for order on the IISRP website at: www.iisrp.com/publications • According to Statista, global rubber production (natural and synthetic) amounted to 28.59 million metric tons in 2017.

(The IISRP is an international not-for-profit trade association with over 60 corporate members, domiciled in 22 countries, who produce 75 percent of the world’s supply of synthetic rubber. Incorporated in 1960 and headquartered in Houston, Texas, the Institute supports section offices in Milan, Tokyo and Beijing.)

www.iisrp.com/publications

2018/11/19 16:45


CLASSIFIED ADVERTS Advertisers: – Dec’18 / Jan’19 Alpha Plast Asiatech Marketing BMS Brenntag SA Cabletech Marketing Carst & Walker DemaPlastech DH Polymers Engen ExxonMobil FdB Consulting Ferro SA GreenTech Machinery Hestico Inkulu Plastic Pipes Ipex Machinery Jenowill Kamboo Marketing Labotek (FdB Consulting) Maritime Marketing Masterbatch SA MBT MGMW Trading Mould Base NGR GmbH Nissei ASB Orion Engineered Carbons Performance Colour Systems PlastiColors Plastomark Propak Africa Rajoo Engineers Rapid Granulator Rawmac Relloy – EREMA Relloy Roediger Agencies Safripol SAPY Colours SES Sun Ace Tecnova Italy Welltec Zerma Africa

24 31 87 IFC 09 IBC 61 89 83 63 68 37 29 59 41 26 03 53 28 01 33 25 55 17 27 65 43 69 19 45,47 30 81 75 23 49 71 35 05 15 67 13 34 85 OBC

PRODUCTION OVER FESTIVE SEASON SHUTDOWN • We can run products for you over the Dec/Jan shutdown and ensure delivery when you return to work early in 2019. • You will need to supply your mould(s). To discuss rates and terms, please contact: Romy Chetty on 011 976 1616 / 082 413 7190 romy@teatime.co.za Chloorkop Ext 1, Kempton Park

THERMOFORMING, SHEET EXTRUSION, AND MATERIALS THERMOFORMING TECHNOLOGY

SAVE 90% of your electricity use with GN! • GN (Canada): machines for reduced waste and reduced energy • Thermoforming Moulds for GN and other thermoformers • ToolVu technology for productivity and NEW quality improvement on thermoforming machines • Complete lines for EPS foam trays and EPS cup moulding NEW

EXTRUSION TECHNOLOGY FROM AGRIPAK OF ITALY Mono & multi-layer extrusion lines for the production of: • ‘Cartonplast’ (twinwall/hollow profile sheet) • Multilayer sheet for packaging • Semi-foamed sheet for thermoforming

MATERIALS FOR THERMOFORMED PACKAGING

• Sealing films for trays and top web for FFS machines • OPS, PP, PET sheet for general packaging • PP/EVOH/PP for high barrier containers

BRE INNOVATIONS Contact: Tim Forshaw (083 381 5253) or Phil Hopkinson (083 408 5253) or 021 671 5253 or mail to tim@bre.co.za

Recycle your plastic with us

We buy most forms of clean factory waste

Contact: Desiré Preston for more info Tel: 011 894 3520 | Cell: 083 774 6038 | Email: desire@jcl.co.za www.jcl.co.za

To place a classified advert please Fax: 086 519 6089 or Tel: 021 712 1408 or E-mail: saplastics@iafrica.com

www.saplastics.co.za DEC 2018 / Jan 2019

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2018/11/20 12:21


Sport The CX Series is endorsed by Dunlop’s Tour Team players including multiple Grand Slam finalist Kevin Anderson who will use the rackets during the 2019 season

Dunlop & BASF

unleash

the performance within tennis rackets BASF’s Infinergy results in higher ball rebound with faster ball response MODERN day tennis players tend to play with more spin and as a result, hit the ball out of the top of the racket rather than the centre. The disadvantage of this is players swing with more force to generate more power and spin. This puts extra load on the player’s arm and can result in injury. The Dunlop research team observed this trend and employed a new innovation to resolve this aspect – the Sonic Core made with BASF’s Infinergy®.

Infinergy is the world’s first E-TPU that sets the standards in cushioning, rebound and performance. Located at the two and ten o’clock areas of the racket, Sonic Core made with Infinergy creates a high performing yet comfortable material. Dunlop’s material testing shows the main highlight is its 46% increase in rebound height vs Dunlop’s original Sonic Core material resulting in 2% faster ball speed off the racket. In addition to superior rebound properties, the Infinergy material also

has impressive damping properties and reduces vibrations up to 37% vs a standard carbon fibre racket. The Sonic Core technology can be found in Dunlop’s next generation CX racket series.

www.DunlopSports.com www.infinergy.basf.com

Trail Shreda mountain bike training aid THE Trail Sheda was designed in conjunction with the Crank Shop and was manufactured by Pioneer Plastics in Rosslyn South Africa. The product won the 2018 ARMSA Product of the Year Competition. The moulds are all made from CNC aluminium and were made in-house by Pioneer Plastics. Trail Shreda is the first pure mountain bike training aid designed for mountain bikers as well as fitness enthusiasts. The Train Shreda simulates real life riding conditions. Having to balance as well as steer while training with both bicycles wheels spinning, you exercise muscles you normally would not use on standard indoor trainers. The rollers are adjustable to allow for different bike types and sizes. This product consists of 8 x rotationally moulded parts and a total of 51 individual parts assembled together. The rollers are moulded in Polyprop to be able to withstand the operating conditions. Under extreme conditions, the rollers rotate at 3200 rpm. There are 7 moulded through holes and 2 stell threaded inserts. There are various graphics as well as moulded engravings for branding and user warnings. The product was developed in conjunction with the Crank Shop, Pretoria based indoor cycling studio to create a product that gave more value to their clients as well as a product that can be used at home, at the office or when on holiday. The product was tested by numerous teams at the UCI Mountain Bike World Cup in Stellenbosch, South Africa with great success. 92 DECEMBER 2018 / JANUARY 2019

www.exerciseforlife.co.za

www.pioneerplastics.co.za


Our Winning Formula Sets Us Apart ELASTOMERS

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(T) 011 489 3600 (F) 011 489 3601

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(T) 041 3999 529 (F) 041 3999 401

www.carst.co.za


The Home of Size Reduction

Classifieds Feb/Mar'18.indd 92

2018/01/29 12:33


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