Southern African Polymer Technology

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BRENNTAG BRENNTAG POLYMERS POLYMERS BRENNTAG BRENNTAG BRENNTAG BRENNTAG POLYMERS POLYMERS POLYMERS POLYMERS

BASF Hexamoll BASF Hexamoll DINCHDINCH Plasticizer Plasticizer – – The trusted The trusted non-phthalate non-phthalate plasticizer plasticizer Due toDue hightosafety high standards safety standards and and extensive extensive testing,testing, Hexamoll® Hexamoll® DINCH® DINCH® is recommended is recommended for close forhuman close human BASF BASF Hexamoll Hexamoll Hexamoll DINCH DINCH DINCH Plasticizer Plasticizer Plasticizer BASF Hexamoll DINCH Plasticizer –– –– contact contact with PVC with products PVC products that contain that contain BASF Hexamoll DINCH Plasticizer – TheThe trusted non-phthalate plasticizer The trusted trusted non-phthalate non-phthalate non-phthalate plasticizer plasticizer plasticizer plasticizers. plasticizers. Itnon-phthalate can be It can used beasused a substitute as a substitute The trusted plasticizer for traditional for traditional phthalates phthalates in many in many DueDue to high safety standards and Due to to high high safety safety safety standards standards standards andand and sensitive applications. applications. Dueextensive tosensitive high safety standards and testing, Hexamoll® DINCH® extensive extensive testing, testing, testing, Hexamoll® Hexamoll® Hexamoll® DINCH® DINCH® DINCH® extensive testing, Hexamoll® DINCH® is recommended for human recommended is is recommended recommended for close for for close close close human human human is recommended forPVC close human contact with PVC products that contain contact contact with with PVC PVC products products products thatthat that contain contain contain contact with PVC products that contain plasticizers. It can be as substitute plasticizers. plasticizers. can It It can can be used used be be used used as aaas as substitute aa substitute substitute plasticizers. It canphthalates be used asin a substitute for for traditional for traditional traditional traditional phthalates phthalates phthalates in many many in in many many for sensitive traditional phthalates in many applications. sensitive sensitive applications. applications. applications. sensitive applications.

BRENNTAG BRENNTAG South Africa South (Pty) Africa Ltd (Pty) Ltd 11 Mansell 11 Road Mansell Road Killarney Killarney Gardens, Gardens, Cape Town, Cape 7441 Town, 7441 Phone: +27 Phone: (0)21+27 020(0)21 18 00020 18 00 info@brenntag.co.za info@brenntag.co.za www.brenntag.com/south-africa www.brenntag.com/south-africa BoksburgBoksburg BRENNTAG South Africa (Pty) Ltd Ltd Cnr 15th Ave Cnr 15th & Cason Ave Road, &Africa Cason Road, BRENNTAG BRENNTAG BRENNTAG South South South Africa Africa (Pty) (Pty) (Pty) Ltd Ltd 11Mansell Mansell Road BRENNTAG South Africa Ltd Boksburg Boksburg North, Johannesburg, North, Johannesburg, 1459 1459 11 11 11 Mansell Mansell Road Road Road(Pty) Killarney Gardens, Cape Town, 74417441 11 Mansell Road Phone: +27 Phone: (0)10 +27 020 (0)10 91Cape 00020 91 00 Killarney Killarney Killarney Gardens, Gardens, Gardens, Cape Cape Town, Town, Town, 7441 7441 Phone: +27(0)21 (0)21 020Town, 1800 00 Killarney Gardens, Cape Phone: Phone: Phone: +27 +27 +27 (0)21 (0)21 020 18 020 020 18 187441 00 00 info@brenntag.co.za Phone: +27 (0)21 020 18 00 Pomona Pomona info@brenntag.co.za info@brenntag.co.za info@brenntag.co.za www.brenntag.com/south-africa info@brenntag.co.za 58b Maple 58b Street, Maple Pomona, Street, Pomona, www.brenntag.com/south-africa www.brenntag.com/south-africa www.brenntag.com/south-africa www.brenntag.com/south-africa Kempton Kempton Park, 1619 Park, 1619 Boksburg Phone: +27 Phone: (0)10+27 020(0)10 91 00020 91 00 Boksburg Boksburg Boksburg Cnr15th 15th15th Ave& &Cason Cason Road, Boksburg Cnr Cnr Cnr 15th Ave Ave Ave & & Cason Cason Road, Road, Road, Boksburg North, Johannesburg, 14591459 CnrBoksburg 15th Ave & Cason Road, Boksburg Boksburg North, North, North, Johannesburg, Johannesburg, Johannesburg, 1459 1459 Phone: +27(0)10 (0)10 02091 9100 00 Boksburg North, Johannesburg, 1459 Phone: Phone: Phone: +27 +27 +27 (0)10 (0)10 020 020 020 91 91 00 00 Phone: +27 (0)10 020 91 00 Pomona Pomona Pomona Pomona 58b58b Maple Street, Pomona, Pomona 58b Maple 58b Maple Maple Street, Street, Street, Pomona, Pomona, Pomona, Kempton Park, 1619 58bKempton Maple Street, Pomona, Kempton Kempton Park, Park, Park, 1619 1619 1619 Phone: +27(0)10 (0)10 02091 9100 00 Kempton Park, 1619 Phone: Phone: Phone: +27 +27 +27 (0)10 (0)10 020 020 020 91 91 00 00 Phone: +27 (0)10 020 91 00 23605_BT_SouthAfrica_Polymers_Hexamoll-DINCH_210x297mm_Es.indd 23605_BT_SouthAfrica_Polymers_Hexamoll-DINCH_210x297mm_Es.indd 1

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22.07.19 15:52 22.07.19 15:52 2019/10/01 09:35


FUTURE

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26.06.2019 11:34:41


BY THE WAY

Publisher & Managing Editor: Martin Wells (martin@summitpub.co.za) Editor: Tessa O’Hara (tessa@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: tessa@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.sapt.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 c: 082 904 9433 e: lynne@summitpub.co.za Printed by: Novus Print, Paarl Southern African Polymer 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

Association of Rotational Plastics Institute

Moulders of South Africa

of Southern Africa

Plastics Converters Association

PET Plastic Recycling South Africa

Institute of Materials

Mike Smart (right) is our new columnist and he is going for a hat-trick, seeing as this will be his third column this issue (see p 44). Mike is a qualified civil engineer with a BSc (Honours) degree and a registered professional engineer who has worked in many sectors of the civil engineering industry, including consulting, municipal engineering and contracting. He has owned both thermoplastic pipe manufacturing and thermoplastic pipe installation businesses. In short, if it involves transmission by pipeline, Mike has done it and knows at least something about what can often be complex problems. He is currently a member of the SAPPMA (Southern African Plastic Pipe Manufacturers Association) technical committee and chairman of IFPA (Installation and Fabrication Pipe Association). His columns focus on the plastic pipe sector and the industry

‘Double your best development cost and time assessments,’ says Conver-Tek’s Davis ACCORDING to Bevan Davis of Conver-Tek, product development and innovation can be tricky. One of the most experienced plastic product developers in SA, with triumphs such as the Kreepy Krauly pool cleaner behind him, Davis had some sage advice for trainee toolmakers at a recent Production Technologies Association event. “Double your best engineered assessment of time to market,” said Bevan, “and also double your best and most accurate budgets for the project.” “You need to be realistic and self-critical of the process, have massive confidence in your R+D and be visionary. And you must always remember that there are never any guarantees of success, sales or market share ... irrespective of your best product research, market analysis, sales volumes and best intentions.” In short, very little (virtually nothing) is guaranteed.

‘We don’t have a water crisis, we have a leakage crisis’ AFRICA’S cities face the same challenges that virtually all major urbanised areas in emerging economies face, one of them being that of getting water to citizens in the most cost-effective manner. Frequently, a shortage of water is blamed, but that is not the actual culprit according to Alister Goyns of Pipes cc, who spoke at the SAPPMA Pipes XII conference in August. According to Alister, “We don’t have a water crisis, we have a leakage crisis” – by which you can gauge that the actual problem is one of poor maintenance and, for many, underestimating the scale of the problem.

Lost in translation IN OUR article in Aug/Sept about Cabletech installing four Haitians at Electrolux, we may have caused some astonishment with our sentence structure! The article suggests that the injection moulding machines are used by Kwikot to produce hot water geysers up to 30,000 litres! This is a huge size and impossible with injection moulding, normally. And so too at Kwikot. The Haitians manufacture the polymer elements used to assemble the massive geysers, such as the element housing and isolation covers – not the actual geysers … IF YOU HAVE SOMETHING TO SAY that are made from aluminum and steel.

Look at the bright side: if you have some gem of wisdom to impart, please write to us at tessa@summitpub.co.za


Volume 17 No 5

OCTOBER – NOVEMBER 2019

CONTENTS Find out more at www.sapt.co.za

16

Industry News 6 10

Latest plastic recycling figures

12 16

PlasX installs major plant in PE

20

PESC lab achieves ISO accreditation – first in SA

Airtect mould leak detection system

64

Cabletech, first Haitian Mars at Ian Brown Engineering

ARMO 2019 2235

Roto tonnage dip didn’t spoil ARMO show

Roto News 36

Roto moulder Plastiflo in J Bay

37

JoJo Tanks acquires Calcamite

PIPES XII 38

Growth, opportunity for plastic pipe industry

Rubber News 46

74 79 96

Sales into Africa climb at Rema TipTop-Dunlop

Environment 48 50

‘Waste Shark’ aquadrone tested Bio-based materials can help plastics’ ‘bad image’

Design 58

Winning bread packaging design

60

IDEA Awards, excellence in design

ON THE COVER: These Lalaboom educational beads were one of the 2019 winners in the International Design Excellence Awards (IDEA) - one of the longest running and most prestigious design awards programmes in existence. Read more on page 62 • www.idsa.org/IDEA


COMMENT

Fiasco or good result – Both these photos were taken on the KZN coast recently. On the left, a potentially disastrous situation where mainly plastics litter is pouring down a dune just north of Durban on to the beach; on the right a clean-up organised by Safripol who collected almost 50 large bags of litter in just two hours

Hats off to Plastics|SA

for driving environmental programme Aim remains to develop new solutions for post-consumer materials

I

4 OCT / NOV 2019

T’S hats off, if you have one, to Plastics│SA for its work in galvanising the industry’s environmental initiatives. You may not be aware of the full scale of the programmes conducted by Anton Hanekom and the PSA team. From TV ads, Facebook, the print media and much more - their efforts to create awareness of the work being done by the industry to change attitudes and generate momentum in the never-ending clean-up and, more importantly, to develop new solutions for post-consumer materials, is remarkable.

The annual recycling figures from PlasticsSA (p 6-7) again show credible growth by the recycling sector. Plastics│SA comments that ‘designing plastic packaging and other products with recyclability in mind and gaining access to good quality recyclable materials before they end up in landfill continue to be the top priorities that drive the future strategy of the plastics industry’. To an extent, however, the drive to inform consumers may be a case of preaching to the converted. Is the focus really on the core problem areas? At the time of the introduction of the plastic bag levy in 2002/3, I endeavoured to take photos to illustrate the problem of plastics litter and went on a drive on the N1… and nearly reached Beaufort

THIS ISSUE

West without much success. On return, a friend advised me that he knew exactly where to find plastics litter: ‘just go to schools in certain areas and informal settlements’, he said, which proved a very accurate assessment (and which would have saved a 500-plus km round trip). That’s exactly where the problem is, and remains: the only problem is that it’s got worse, and spread. For sure, the end or even an effective solution are nowhere in sight yet, but the industry needs to feel positive about what we’re doing, that we have a strong recycling sector and that convertors are becoming more aware of the potential to use recycled materials, and not only when forced to by brand holders.

Industry needs to feel positive about what we’re doing

Pipe, roto events A number of sector conferences took place recently, including the roto (ARMSA, p 22) and pipe (SAPPMA, p 38) events, where both recorded above-expectation attendance. The roto conference, held at Sun City, doubled up as the event of the global roto association’s annual meeting, which attracted a sizeable group of international delegates, and the turnout of over 180 was an achievement of note. Getting more people to attend industry events is a good means to spread the news about the positives of plastics products moulding, so well done to all for putting on such fine shows. Martin Wells, Publisher


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2018/10/23 PM 2019/09/261:00 11:11


NEWS

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AN anti-dumping duty (ADD) on polyethylene terephthalate imported from China has been introduced, with a rate for 22,7% of FOB (free on board) cost of the material being implemented. Local producer Safripol, which manufactures PET at its plant in Jacobs, Durban, applied to the International Trade Administration Commission (ITAC) for the imposition of the duty in mid-2018. ITAC commenced an investigation in November last year. It was alleged that PET from Chinese manufacturers was being offered for sale in South Africa at prices below those which these manufacturers achieved in their domestic market. The duty will be applied on a six-month period from 2 August, during which time PET users are able to comment to ITAC. It appears that ADDs on PET from the Far East have become virtually the norm: presently antidumping duties are applied on PET imported from Taiwan (75%), India (54.1%) and Korea (19.7%).

Industry body releases

recycling

More than 519 370 tons’ plastics waste collected for recycling

400 000

Assets of Watertainer project sold off

Waste experted to be recycled elsewhere

375 00 350 000

Recycled in SA

Tonnages

325 000 300 000 275 000 250 000 225 000 200 000 175 000 150 000

2009

2010

2011

2012

2013

2014

2015

2016

2017

80 000

2018

100 Formal employment

70 000 Numbers of jobs

THE Watertainer project, through which the injection moulded 1500-litre ‘Tuff Tank’ water container was launched in South Africa in mid-2018, is on hold. It is understood that the equipment used for the production of the ‘nestable’ tanks, including a 3000ton Haitian machine, was sold by auction. A major undertaking by the former owners of Perma Products, Trevor Britland and David Bray, production of the Watertainer tanks had been based at a new site in Cato Ridge between Durban and Maritzburg. Optimism for the success of the project had been high and the developers had been confident that the concept would achieve market acceptance, but it appears that several problems were encountered and beset its takeoff. The new owners of the plant were travelling during September; an announcement is expected.

In addition, 100% certified recycled plastic material is now used to produce some carrier bags. This creates an end-market for recycled plastic products and helps to reduce waste to landfill. By ensuring that the products we create become part of a circular economy, we create a win-win situation for the environment and for the industry that employs 60 000 people,” said Anton Hanekom, Executive Director at Plastics|SA.

ALTHOUGH more can and should be done to encourage South African households to recycle, the latest Plastics/SA recycling figures clearly show that South Africa has a dynamic, growing and well-supported plastics recycling industry. “Despite facing major challenges last year, the plastics industry made important strides forward. Plastic bags manufacturers removed fillers to produce bags that are fully recyclable.

58 457

Informal employment

60 000

52 297

80

Tons/employee

50 000

90 70

40 000

60

30 000

50

20 000

40

10 000 0

2009

2010

2011

2012

2013

2014

2015

2016

5837

7892

2017

2018

30

Tons per formal employee

OCT / NOV 2019

JUST BRIEFLY

Anti-dumping duty on PET from China

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latest plastic figures Key findings of the 2018 Recycling Survey are: More than 519 370 tons of plastics waste were collected for recycling

46.3% of plastics waste was collected for recycling, making South Africa one of the best mechanical recyclers in the world

Plastics recycling in 2018 saved 246 000 tons of CO2 – the equivalent emissions of 51 200 cars

R2.3 billion rand was injected into the informal sector through the purchasing of recyclable plastics waste 352 000 tons of new recycled plastic raw material were manufactured to complement virgin polymer in South Africa, a 12.2% increase year-on-year

RECYCLING IN SA

Recycled tonnages grew 64% and virgin polymer 21% since 2009

70% of all recyclable materials originated from landfill and other post-consumer sources

Designing plastic packaging and other products with recyclability in mind and gaining access to good quality recyclable materials before they end up in landfill, continue to be the top priorities that drive the future strategy of the plastics industry. A South African Initiative to End Plastic Waste in the Environment was recently established. Representatives of the plastics and packaging industries, raw material suppliers, converters, brand owners, international fast-moving

Growth in plastics recycling – 6.7% more than the previous year South Africa has 300 active recyclers of which 20% were doing 70% of the tonnages reported

34.1% of South Africans do not have access to regular waste removal

The amount of plastics that were recycled in South Africa during 2018 alone saved enough oil to fuel 200 000 cars for one year – traveling 30 000 km/annum

The plastics recycling industry provided direct employment to more than 7 800 people and created a further 58 500 income-generating jobs

consumer goods companies, recyclers and environmental organisations are developing a workable, local plan that fits the South African context and our particular environmental, sociopolitical and economic realities. “Recyclables are a valuable resource and should be removed from the solid waste stream before reaching landfill where they become contaminated and extraction costly. Similarly, stakeholders have to work together to manufacture locally,

Looking ahead To ensure that the value of plastics is repeatedly harvested and that a sustainable, growing circular economy is developed, Plastics|SA has made the following recommendations: Improve South Africa’s waste infrastructure. Used plastics need to be collected and removed from the environment. An adequate waste management infrastructure (that is able to deal with recyclable as well as difficult to recycle waste) must be developed and put in place at municipalities around the country. Reduce contaminants in the waste stream. Plastics recycling can continue to grow through collaborative effort to reduce the contaminants in the incoming waste stream, e.g. compostable and biodegradable material. Provide assistance to recyclers in terms of challenges within their recycling operations. Develop alternatives for difficult to recycle plastics. There are certain materials and plastic products that are not economically viable to collect, transport or recycle. Solutions need to be developed for these difficult-to-recycle materials.

process efficiently and manage the end-of-life products so that they benefit the consumer, the industry and the planet,” Hanekom concludes. • The Executive Summary (containing more information and detailed breakdown) can be downloaded from https://www.plasticsinfo. co.za/wp-content/uploads/2019/08/ Plastics-Recycling-in-SA-July-2018Executive-Summary-final.pdf www.plasticsinfo.co.za OCT / NOV 2019

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NEWS

JUST BRIEFLY

Nampak drums and crates business no longer for sale NAMPAK has terminated its plan to sell its plastic drums and crates business. It first announced its intention to terminate the business in its results reported for the year to September 2018, Since then, however, the business – which operates plants in Olifantsfontein, Pinetown and Epping – has picked up a large contract with a soft drinks manufacturer and succeeded in reducing costs. As a result, it has decided to ‘withdraw the business from a proposed disposal process’. Clinton Farndell, MD of Rigids at Nampak, said a new leadership structure had been put in place, and likewise at the business’s operational level. The Rigids business has started to see the operational and supply chain benefits from the initiatives implemented, allowing it to pursue further growth opportunities, he said. And a new branding campaign has been launched, ‘Our Plastics Makes Perfect Recycling,’ focusing on the important role Nampak has to promote sustainability in the environment in which it operates.

8 OCT / NOV 2019

SAPRO Recycled Product of the Year awards, tickets on sale ENTRIES for the SAPRO Recycled Plastic Product of the Year Award are now closed. Ticket sales are open for the awards dinner – and it promises to be a night to remember! The awards will be hosted on 4 Nov, at Workshop 17, at the V&A Waterfront in Cape Town, from 6pm. To book tickets, visit www.quicket.co.za/ events/85388-sapro-best-recycledplastic-product-awards-2019/. You can also contact Lisa Parkes at tel: 083 406 3298, or email: lisa@plasticrecyclingsa.co.za

unveils plan to put up PET plant at Coega R1,3-bn forecast project for 240K tpa plant UTSHONGO Polytech has lifted the lid on its ambitious plan to construct a PET manufacturing plant at the Coega IDZ near Port Elizabeth in what is estimated to be a R1,3-billion undertaking. “We are going ahead with the project,” said Mphumezi Penny of Utshongo, based in Midrand. “The South African PET market needs a second supplier. The country cannot have a single supplier, that risk is huge. A significant amount of PET is imported into SA and we are confident we will replace these imports, it’s good for the country and for PET convertors,” added Penny, who was formerly at Hosaf (now the Safripol Durban PET manufacturer). Chemtex Global Corporation (USA) has been nominated as the technology provider, contracted to supply a turnkey plant to produce 240 000 tpa of PET. The plant will produce all grades of PET required by the sub-Saharan market, including CSD grade; fastreheat grade, that is now widely used in SA; low IV grade for the still water bottling industry; bio-PET grade using bio-MEG (modified ethylene glycol) originated from renewable plant sources. The latter grade of PET is a way of reducing the carbon footprint, said Penny. Siting the plant at the Coega Industrial Development Zone is seen as an advantage as incoming materials (MEG and purified terephthalic acid) will be transported by a 3km pipeline from the deep-water port. “It is possible to dock any size vessel and that means we will have no limitation in

terms of shipment that we will bring into SA. More importantly, Port Elizabeth is perfectly located to transport PET to the Western Cape to serve convertors there, and there are also PET users close to PE. Exporting to other coastal African countries will be a lot easier, and this market is known to us. There is no reason to not supply,” said Penny. The socio economic benefits of the project for PE are huge, he added. These include direct permanent jobs; skills development for graduates from University of Nelson Mandela Bay; in-service training for artisans, electricians, chemists, engineers and finance; and the creation of new entities that will create new additional jobs in logistics, security and cleaning services. “We have already started talking to various PET convertors and the support is amazing, confirming the need for a second producer. We have also secured raw materials supply for the project,” he added. “In addition to the above, I want to say we are serious about the environmental impact that PET bottles have on our environment. To this extent, we will invest heavily in a hightech recycling plant/technology. “Given that PET is commodity, competition with Safripol is unavoidable. Who is best placed to compete with them, a foreign or local company? We know the industry very well, and our objective is to deliver exactly what customers want and nothing less than that.”

• Besides its core mining operations, Utshongo (established in 2012) has expertise in plastics technology and is involved in PVC tile production.

Mphumezi Penny of Utshongo


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NEWS

Injection Technik of Port Elizabeth introduced the Airtect system at a trade show in Cape Town earlier this year. Stephan Aucamp says the compact systems have been popularly received and practically eliminated the risk of hot runner mould failure due to over-heating

Airtect mould leak detection system from Injection Technik

10 OCT / NOV 2019

Designed to monitor the injection process SPECIALIST mould repair/maintenance business, Injection Technik, is now also supplying the Airtect leak detection system for hot runner moulds. Manufactured by the eponymously name Airtect of Ireland, the system is a modular and fixed leak detection technology designed to monitor the injection process, starting with the barrel and nozzle up to the hot runner mould, divided up into as many as 32 zones. It functions with robust 2mm stainless steel sensor tubes. “It achieves direct plastic leak presence detection,” said Stephan Aucamp of Port Elizabeth-based Injection Technik. The problem of hot runner failure is obvious and can result in extensive

downtime. However, according to Aucamp, the Airtect technology allows the setter to assess how serious the problem is: if only a minor amount of material is leaking, a production run can be allowed to continue uninterrupted and repair delayed until spares and specialist mould repair service are at hand. If the problem is serious, the system clearly indicates where the problem is and thus offers a suitable means of avoiding more serious damage. The Airtect quick-release modular system attaches on to the base manifold. Installation is easy and the system operates 24/7, creating 24-hour piece of mind. Leak detection is displayed on LED or

LCD clear text. Aucamp says some of SA’s top converting groups have installed systems and are operating happily. www.injectiontechnik.co.za

South African company paves the way with plastic road Recycled Plastic Surgery for our Roads IN A ground-breaking, market-leading initiative, Shisalanga Construction has paved a South African road using a locally recycled plastic compound as part of the formula ingredient in the asphalt. The maiden recycled plastic road paving trial was successfully completed in Cliffdale, KwaZulu Natal

in August. Shisalanga’s technical manager, Wynand Nortje, said that Shisalanga is the first South African company to successfully complete an application of recycled plastic road by using a binding agent that has unique properties and through this, creating a usable and durable solution for the

road construction industry. The type and quality of the recycled HDPE plastic is critical in ensuring that the binding process is successful. The recycled plastic is readily available from South African recyclers and provides an appropriate use in this road construction application. In a ground-breaking, market-leading initiative, Shisalanga Construction has paved a South African road using a locally recycled plastic compound as part of the formula ingredient in the asphalt. The maiden recycled plastic road paving trial was successfully completed in Cliffdale, KwaZulu-Natal in August


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NEWS

Start-up PlasX installs major plant in PE It’s virtually wall-to-wall Haixings at new Port Elizabeth plant PlasX, a new injection moulding business in Port Elizabeth, has recently commissioned its plant – including 14 Haixing injection moulding machines – in what must be one of the most impressive ventures in SA this year. The start-up business, in totally refurbed industrial premises in Korsten, is a collaboration between a number of shareholders, including Auto-X, and is being managed by PlasX plant manager Peter Brummer (right) with machine supplier Ricky Lazenby of MJH of Durban and Richard Zhu of Haixing of China, who was at the plant in Port Elizabeth during the commissioning phase in September. The new plant includes machines between 88 and 650 tons clamp force

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Peter Brummer (ex-Q-Plas, Faurecia). PlasX opted for the Haixing machines, built in China and supplied by MJH of Durban, due to historical experience and Haixing’s “fit-forpurpose equipment and cost,” said Brummer. The company’s core activity is injection moulding, mainly of automotive parts at the outset, with simple assembly capability. The venture will eventually create 65 new jobs in PE. Local toolmakers involved in the project include Kenzel Engineering and CRMoulds. PlasX has opted for a sophisticated materials handling system from Motan; and (right) changing moulds, which a is huge necessity in the automotive component supply sector, is expedited by the new gantry

OCT / NOV 2019

2019/10/06 11:23


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NEWS

Aberdare launches the High Voltage manufacturing plant

14

OCT / NOV 2019

Aberdare Cables is a 72 year old South African leading cable manufacturer, with three manufacturing sites in South Africa, and customer service centres in each province

Minister of Trade and Industry, Mr Ebrahim Patel; his deputy, Mr Fikile Majola; MEC for Economic Development in the Eastern Cape, Mr Mlungisi Mvoko; Ambassador of the People’s Republic of China to South Africa, Ambassador Lin Songtian, Executive Mayor of the Nelson Mandela Bay Metro, Mr Mongameli Bobani and Aberdare Cables CEO, Dr Haiyan Song at the launch of the multimillion investment, the Aberdare High Voltage in Port Elizabeth

MINISTER of Trade and Industry, Ebrahim Patel, officially launched the multi-million-rand Aberdare High Voltage Power Cables Plant in Port Elizabeth on Thursday, 25 July, at the event which was attended by high-level delegations from government, Chinese Embassy, labour and business. This new industrial investment sees the expansion of Aberdare Cables’ manufacturing capability increase from a current level of 33kV to a new product offering of up to 132 kV. This R135 million investment is expected to create 58 jobs in addition to the 429 jobs that Aberdare Cables has created in its Port Elizabeth branch to date, at both plant and commercial levels. Speaking at the event, Minister Patel said government welcomed the new investment by Aberdare Cables as it would add a significant value in the South African

economy and that he viewed the investment as an opportunity to bring young people and women into jobs. Aberdare CEO, Dr Haiyan Song, commented: “As a private sector we need to play a leading role in growing the South African economy to address the major social challenges facing this country. As Aberdare Cables and Hengtong Group we commit ourselves to contributing immensely in the government’s campaign for growth and renewal, to help build the country and create jobs, especially for young people and women. Hengtong is planning to invest further in South Africa over the next few years.” www.aberdare.co.za

Soweto recycling entrepreneur cleans up with equipment boost CLEANING UP: Soweto entrepreneur and Pendowave Recycling owner Gordon Nkuta (centre) received a business boost in the form of machinery and equipment worth over R200 000 from PETCO and PET plastic converter ALPLA. Pendowave Recycling provides a regular income for 26 people – six contract employees and 20 waste collectors. According to Nkuta, the plan is to be able to take on permanent staff and move to the next level - manufacturing. Here ALPLA’s head of transformation Wilma Mahomed (left) and PETCO’s Belinda Booker inspect his new trailer for improving waste collection.

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2019/10/06 11:26


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NEWS

SA Plastics Pact moving ahead THE combined efforts of the WWF and SAPRO are bearing fruit in developing the South African Plastics Pact, a statement by the partners said. The founding members who have signed on, will form part of the interim steering group that will be tasked with appointing the secretariat and advising on the targets, fee structure and planning the official launch of the initiative (pegged for October / November 2019).

JUST BRIEFLY

Should you wish to come aboard as a Founding Member or to find out more about the initiative, contact Lorren de Kock at the WWF ldekock@wwf.org.za or Lisa Parkes at SAPRO, lisa@plasticrecyclingsa.co.za

Marine ‘Litter Trace’ project may be back on track

16 OCT / NOV 2019

THERE is a possibility the Litter Trace project, in which polymer blocks are to be released into the ocean around the Cape peninsula in order to monitor the flow of plastics litter, may still get underway. The study project, referred to in the last issue, was stalled after environmental groups obtained a legal interdict preventing it from proceeding, but Peter Ryan of the FitzPatrick Institute of Ornithology at UCT says they are “just waiting for a window when we have sufficient people free to do the necessary beach checks”.

Cabletech commissions at Ian Brown Engineering Ideal for manufacturers of plastic products that do not require extensive processing pallet jacks and general material CABLETECH installed a Haitian Mars handling applications manufactured 2500/1000G injection moulding machine from nylon, polypropylene, TPU and at Ian Brown Engineering, owner and TPE. We also manufacture our glassmanufacturer of the Rybro brand of reinforced polypropylene and aluminum castors and wheels. This increases the customisable dolly (the portable company’s fleet to seven injection frame used to move crates) moulding machines, with the which we designed and MA2500/1000G unit being Our product patented in 2016,” says the largest. Ian Brown. Based in Kya Sands offering includes Cabletech’s Lorraine in Johannesburg, Ian single-bodied and du Plessis oversaw the Brown Engineering – over-moulded wheels successful installation widely known as ‘IBE’ and rollers for and commissioning – has been owned of the Haitian Mars and run by the Brown castors, trolleys & MA2500/1000G family since its inception pallet jacks. machine at IBE. in 1988. Currently headed “The Haitian Mars up by Ian Brown, the II Golden series injection company handles all the design moulding machines are the machines and development of its plastic products for companies manufacturing plastic in-house in its comprehensive CNC tool products that do not require any room and production facility. extensive processing,” she explained. “Our product offering includes “The Haitian Mars II Golden series single-bodied and over-moulded is a reliable and cost-effective machine wheels and rollers for castors, trolleys,

The white plastic blocks to be used in the project measure 12x8cm and come in two types, hard plastic sheets 3mm thick with stickers on them bearing a unique item number and information on how to report them; and polystyrene blocks 30mm thick that are only labelled with a unique code (as the labels the researchers had did not stick to EPS). Cabletech’s Lorraine du Plessis, with Ian Brown Engineering’s Ian Brown and son, Brice

Clas


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first Haitian Mars which gives anyone the ability to manufacture a great quality product with a new machine, with an inclusive 12-month warranty without spending an absorbent amount,” she added. The machine is fitted with an energysaving servo system that is controlled by frequency inverters which only draws the power needed for the process. It is also fitted with a Techmation operating system that is capable of all the monitoring options and control configurations one can expect on any injection moulding machine. www.rybro.com

Trade. Create. Elevate.

The glass-reinforced PP and aluminium customisable dolly (the portable frame used to move crates), which IBE designed and patented in 2016

A range of the mouldings manufactured by IBE, including its ‘Institutional’, nylon, PU, elastic urethane wheels and ‘Pallet Jack’ roller

www.cabletech.co.za

> www.meraxis-group.com

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OCT / NOV 2019 17

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2019/09/12 11:55


NEWS

JUST BRIEFLY

Coega IDZ most successful in Africa

THE Coega Industrial Development Zone in Nelson Mandela Bay is now deemed the most successful Special Economic Zone (SEZ) on the continent, with 40 operational investments valued at approximately R6.996-billion and a further 22 investments in progress. The most recent investment is from Beijing Automobile International Corporation, with a 65% share in an R11.5-billion joint venture with the Industrial Development Corporation, to manufacture vehicles. Phase one of the project is estimated to churn out 50 000 units a year. Full production will begin in 2023. In another major development, First Automotive Works (FAW) is currently erecting a R600million assembly plant in Zone 2. The metals and manufacturing sector of the Coega IDZ intends to implement three new rojects; a R650-million cement grinding plant, a R350-million gas cylinder plant and a R71-million ‘readymix’ concrete plant.

Poor trading conditions impact Transpaco’s results

JSE-listed packaging producer Transpaco witnessed poor trading conditions and reduced consumer spend during the financial year to end-June but still declared a 50c share dividend, to be paid out of income reserves, resulting in total dividend of 80 cents a share for the period. The difficult operating environment, and the three-month industry strike in late-2018, resulted in a decline in the group’s overall performance. Transpaco’s challenges were further exacerbated by the ongoing anti-plastic debate, it said in the results statement. Transpaco is manufacturing retail shopping bags from compostable materials as an alternative solution to retail plastic bags and said it was “exploring the viability of establishing a retail bag production facility to manufacture bags from two alternate materials”. 18

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Chromaflo acquires SA colour firm Liquid Colours Solid platform in volume and technology, coupled with a diverse range of products to regional footprint GLOBAL colorant provider Chromaflo Technologies, has made its second international acquisition in less than a year, this time buying Liquid Colours (Pty) Ltd of South Africa for an undisclosed price. Liquid Colours’ colorant dispersion division includes pigment dispersions and colorant technologies for decorative paint point-of-sale, in-plant systems, industrial coatings and other applications. That business will be integrated into Chromaflo’s recentlybuilt plant in Johannesburg. Chromaflo Technologies South Africa will be headed by former Liquid Colours general manager, Lyle Peters. The transfer of product lines, technology and personnel from the Liquid Colours’ dispersions division to

Chromaflo will take place over the next 12 months, officials said. Chromaflo’s South Africa operations are part of the firm’s Asia-Pacific regional business, which is headquartered in Melbourne. “The combination of our existing business and that of Liquid Colours’ dispersion division is a significant and exciting development for our business in Southern Africa,” said John Dry, managing director and VP, APAC. “It provides us with a solid platform in both volume and technology, coupled with a diverse range of products to further increase our regional footprint.” www.liquidcolours.co.za www.chromaflo.com

Roof on top of roof at Vacuform 2000

Vacuform 2000 in Rosslyn, which has been in operation since 1974 and run from the same premises since 1984, recently had to take the unusual step of installing a new roof over its existing roof. The company is a supplier to the automotive industry and is now part of the global Motherson group; and the two partners who purchased the company from the previous owners in 2000 (hence the name), Molefe Mokgatle and Anthony Taylor, remain as the managers of the business. They put off expansion at the 5000m² site for several years, whilst the company’s staff increased from 35 to over 160, to the point where it was becoming counter-productive. The company is involved in blow moulding and vacuum forming, and some of its larger blow moulding machines needed more vertical space. But they were also not able to stop production for long enough to replace the roof, so the decision was made to construct a new roof above the existing one and then, once that structure is complete, to sequentially move the machines and the other plant. The incredible thing, says Anthony Taylor, is that the structure for the new roof was installed in a single day.

www.vacuform.co.za

OCT / NOV 2019

2019/10/06 11:29

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Infrared heater bands for high energy saving Energy saving up to 70% on barrel heating INFRARED heater bands have now become available in South Africa from new supplier to the plastics industry, GCV Machinery Services, owned and run by Candice and Gert Venter. The heaters can be installed on injection moulding and blow moulding machines, as well all extruder equipment, and promise an energy saving up to 70% on barrel heating, especially on large machines with large screw diameters. The infrared heaters are simple to install – no modifications are necessary to replace the conventional heater bands with infrared heaterbands; the PID settings on the controller do not need to be altered, and no solid state relays or contactors need to be replaced. The heating time from cold to the required temperatures is 50% less. The heater bands are manufactured to a specific machine’s requirements and voltage, wattage, length and barrel power supply connection can be terminal or plug. • For more information, email info@gcvmachineryservices. co.za The infrared heater band has very low heat dissipation, hence the energy saving. Tests have been carried out that show a temperature setting of 425°C with the outside temperature of the infrared heater at just 32°C OCT / NOV 2019

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NEWS

JUST BRIEFLY

Plastics industry at tipping point

A SENIOR manager at Coca-Cola Company in North America says the industry is at a ‘tipping point’. “The plastics industry for single-use bottles, for beverage containers, is under attack. There’s a negative perception that is real for the industry. Consumers are avoiding buying our products,” said Penny Walter, manager for strategic procurement sourcing for closures. “As an industry, we need to come together and have one voice, to educate consumers about the benefits of plastics and to properly recycle,” said Walter at the Plastics Caps & Closures conference in Chicago. “We want 50% recycled content. It’s a big gap. Where’s that material going to come from? We’ve got to close that gap,” she said. “If you want to do business with CocaCola, I highly suggest you take this seriously,” added Walter.

ExxonMobil’s €160 million upgrade at UK ethylene plant

EXXONMOBIL is to make a £140-million (US $173-million) investment in upgrading key infrastructure at its ethylene production plant in Mossmorran, in eastern Scotland. The project, to run through 2019 and 2020, will improve plant reliability and reduce the frequency of flaring, which has seemingly been an issue at the site. The plant was reportedly shut down for a month in mid-August for ‘remedial maintenance’ as a result of an unplanned flaring. A portion of the £159-million (US $196-million) investment, according to ExxonMobil, will go toward implementing technologies that reduce the impact of flaring, including a state-of-the-art flare tip, which will reduce noise and vibration. In operation since 1986, the Fife plant uses natural gas liquids (NGLs) from the North Sea as feedstock to produce 830 kilotonnes of ethylene per annum. 20

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OCT / NOV 2019

The team at the PESC lab in Pretoria incluces (in front) Justin Marsberg (technical manager), Maria Marsberg (financial director), Dr Isbé van der Westhuizen (lab manager) and Masilo Makwela (polymer technologist); back row: François Prinsloo (quality manager & senior technologist), Graham Marsberg (MD), Godfrey Bulose (lab technician) and Sipho Zingwe (workshop assistant)

PESC lab achieves ISO accreditation – first in SA New, state-of-the-art testing equipment, compliant with latest international standards

PRODUCTIVITY Engineering Services and Consultants (PESC), an independent polymer and plastics testing laboratory, successfully obtained SANAS accreditation for ISO/IEC 17025 at the end of July, a first of its kind in South Africa. François Prinsloo (Ndip & BTech Polymer Technology), PESC lab quality manager, says ISO 17025 accreditation is awarded for the competence of testing and calibration laboratories. Owned by husband and wife team, Graham and Maria Marsberg, the laboratory is based in Centurion, Pretoria, and not only services the Gauteng region but also national and international clients. PESC was established 18 years ago, with the laboratory founded in July 2015. The company is efficiently run by a team of highly experienced, competent staff in the fields of polymer testing, electrical and mechanical engineering. PESC applies the knowledge and experience of productivity enhancement and production monitoring in its own facility, with real-time monitoring of laboratory conditions, ovens and pressure units. The laboratory boasts new, state-of-theart testing equipment, compliant with the latest international standards. “The lab can do a wide variety of testing for the polymer industry, including but not limited to. quality control testing such as melt mass-flow rate,

polymer density, mechanical strength determinations, carbon black content, pigment and carbon black dispersion, material melting points and oxidation induction time, material identifications, impact strength determinations, material softening point determination, ash and filler content, and many more. PESC has also recently acquired a UV testing machine to accommodate customers in need of such tests.” says Prinsloo. Other services include: • Failure investigations of polymeric goods such as plastic piping, liners, synthetics, etc. • Customer specific and specialised audits • Custom equipment builds, such as hand brake testers, pressure testing apparatus, coefficient of friction testers, automation and control systems • Professional reporting structures specifically developed on national and international engineering and science practices The lab now also offers specification development to the polymer and plastics industry, where the lab advises customers on specific testing that would be required to determine a product’s properties and performance. After some research, development and testing, PESC writes a unique standard that has been specifically developed to meet the products’, customers’ and end-users’ requirements. www.pesc-lab.co.za

2019/10/06 11:39


Mould Base SA gets Woojin agency Largest plastic machinery manufacturer in South Korea frames and everything else, it is all made in the Woojin plant on a huge estate about 200km south-east of Seoul,” he adds. Moore says the Woojin factory was purpose built a few years ago and houses all the divisions required to make a high quality machine. Woojin has an in-house testing facility and training centre where all the staff are thoroughly trained to build machines to European standards. “An R&D facility was built next to the B&R factory in Austria where Woojin and B&R work together to produce controllers specifically for the Woojin product,” Moore points out. Woojin was established in 1985 and has grown to become the largest plastic machinery manufacturer in South Korea. Woojin offers a wide range of machines, including vertical and servo hydraulic in three spec levels, as well as electric and two platen from 450 ton to 4 300 ton. Woojin is popular in Europe and sells well in the auto industry. • Tel: Dave Moore, 083 675 8325 • Woojin Plaimm will exhibit a comprehensive range of its product at the K2019 show in October. Visit Woojin in Hall 15, stand D58. OCT / NOV 2019

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www.woojinplaimm.com

WOOJIN Plaimm, the South Korean machine-building giant, recently appointed Mould Base SA as their South African representative. Dave Moore, who heads up Mould Base, had this to say about his experience with Woojin: “For the past 18 months I have been looking for a range of machines that will appeal to the customer who prefers to not buy Chinese-made equipment. The Yizumi range, which we have been selling for around four years now, has done very well here and is now one of the top selling brands in the South African market,” he says. “In spite of this, there are companies who prefer, for various valid reasons, to purchase German or other European brands, and even Chinese-made machines with a parent company overseeing it. I believe I have found the perfect machine which will pass any test and can compete with anything out of Europe or Japan at a more affordable price.” “The brand is Woojin Plaimm and it is made in South Korea. The factory is unlike any I have seen before. Almost every part of the machine is made in-house and controlled entirely by Woojin themselves. From castings to screws and barrels, to machine

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2019/10/06 11:36


ARMO2019

Roto tonnage dip didn’t spoil ARMO show Global leaders talk openly about their successes

22 OCT / NOV 2019

WITH roto material consumption for the southern Africa region having taken a serious battering over the past 18 months, it’s been a challenging period for the local roto moulding community, but the ARMSA gang rolled out the red carpet for the many visiting international guests on the occasion of the hosting of the ARMO2019 global roto event at Sun City in September.

The event was the annual conference of the Association of Rotational Moulding Organisations (ARMO), hosted this year by ARMSA (Association of Rotational Moulders of Southern Africa). Just over 180 attended. Figures from industry analyst Clive Robertson show that consumption had increased by a spectacular 28,7% to 47,000 tons p/a in the year to end-February 2018, and then crashed by an only slightly less figure (25,5%) for the 12-month period to end-Feb this year. Most of the boom in the earlier period was due to the drought in the Western Cape, where convertors barely managed to keep up with water tank demand. Booms occur wherever there

The dip in the bars from 2018 to 2019, after the impressive peak of 2017-18, has challenged local roto moulders

is a water crisis, which is a feature of the roto sector, to the point that most of the businesses have become familiar with the phenomena. On this occasion, there was some consolation that the decline was less precipitous than the rise. According to Robertson, of ACD Rotoflo, who monitors and provides the stats annually for ARMSA, the pattern has steadied in the six months since and even shown a slight increase of 4,6% with 18,300 tons of material moving, but opinion seems to suggest that the slowdown in the market may continue until the end of the year, and possibly longer. A further aspect of consumption in the

Consolation that decline was less precipitous than rise

sector is different materials (other than LLDPE) are being used more commonly. Barely skipping a beat has virtually become the norm in the roto manufacturing sector and that was a relief, since the close to 100 international guests were hugely impressed by the reception received at the roto companies visited and at the Cascades at Sun City where the event took place. Experience from afar In his presentation, Celal Beysel of Floteks of Turkey gave an object lesson about life in the roto moulding industry. According to Celal, a former director of ARMO and frequent visitor to South Africa, due to the relatively low cost of entry to the market, roto moulders need to innovate and dare to be different in order to escape from the “endless competition”. Floteks has


Among the products from Floteks are cabin roofs for vehicles such as tractors and interior components such as seating and paneling and housings

Celal Beysel of Floteks of Turkey gave an A-Z explanation about what’s involved in supplying the automotive OEMs

Gary Lategan of Roto Solutions supplies his TempLogger temperature monitoring/control system to Filip Claus of Plastigi

Plastigi of Belgium is making extensive use of robots at one of its four factories, and comparisons suggests it’s proving to be the most cost-effective

Both Floteks and Plastigi make extensive use of the TempLogger from Roto Solutions of SA. there are a big range of automotive components that can be roto moulded, including fuel tanks, expansion tanks, ‘adblue’ tanks*, air ducts, mudguards, seating systems, cabin ceilings/roofs, lockers/boxes and much more. Celal does not see electric vehicles as a genuine threat to the combustion engine at present, believing that distance ranges achieved are not sufficient and that the batteries are too heavy and disposal of them is in itself a major environmental issue (at this stage it’s believed the batteries need to be replaced every two years).

“E-mobility will not affect roto moulding diesel tanks for at least 25 years, maybe even 50 years ...” said Celal, who believes the ideal solution now is tanks with long integrated baffles with a leakfree adblue section as a single-piece product, who knows? * (Adblue tanks are recently developed techniques used to clean up diesel emissions known as selective catalytic reduction (SCR): a solution of urea in water is used to treat exhaust gases and remove harmful pollutants, including nitrogen oxides (NOx), of which nitrogen dioxide (NO2) is the most harmful.) >> pg 24

OCT / NOV 2019 23

graduated to become of the leading roto manufacturers in Turkey and become a significant supplier to the automotive manufacturing sector, but don’t expect any favours, he added, “Most of the time they are not loyal at all”. “That’s why,” said Celal, “only 2-5% of the roto moulders worldwide can deliver to the automotive industry.” Floteks has put all the building blocks to be competitive in place, including high standard production machinery and design and mould making capability, QA and QC structures, assembly abilities, R+D and you name it. And the plus is:


ARMO2019

24 OCT / NOV 2019

R66,000 donated – Meg Lategan (right) of the Zululand Rhino Orphanage, here with Roanne Wiid, was thrilled by the huge success of the charity drive at the conference, with over R66,000 raised during the two days

Robotic roto Another fascinating presentation was that by Filip Claus of Plastigi of Belgium, where extensive, almost total, use of robots is being made. Established way back in ’45, Plastigi today operates four factories (three Belgium, one in Holland, with the ‘robot project’ underway at its factory in Herentals, Belgium since 2012). With robots, it is able to produce a wide variety of products up 1000 litres, weight up to 35kgs and handling moulds up to 400kg. (At its rock & roll factory in Houthalen (est 1984) it can use moulds up to 2,5 tons and make products up to 10,000 litres).

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Fugitive for 5½ years – After guest speaker Stephen McGown’s presentation, about his harrowing experience being held hostage by Islamic militants in Mali for close to six years, virtually nothing could have seemed to be a problem for anyone in the audience. Stephen was travelling by motorcycle down the west coast of Africa when taken hostage in Timbuktu and held in the remote desert in Mali, ostensibly to extract ransom. Since money was not forthcoming, he practically disappeared from 2011-17. Stephen gave a moving account of his experience, and other challenges that had to be overcome after his release. Fortunately for the man, his wife Catherine waited for his return

Tonnage dip doesn’t spoil ARMO show Splitting production between the sites seems to be working for Plastigi, even encouraging competition, said Filip, who presented a detailed comparison between the three technologies used, traditional, rock & roll and robot. The main advantage of robot production is the reduced need for labour, and hence the ability to run 24/7 with far greater ease. In terms of energy and labour cost, according to Filip, robot production is the most cost-effective (excluding the cost of purchase of the robot units). “When we add all of this up, we automatically come to the robot production system we are using now. Today we can produce up to about 1000 litres and a maximum size of 1m x 1m x 1m. We are perfectly able to run these products with the five production robots we have for the moment, next to one dismantling robot and two trimming robots. In 2021 we will produce 70% of our production with robots,” said Filip. “Once we want to manufacture larger sized products, the weight of the mould gets critical. We then come in a robot range that’s less standard and more expensive, but still doable. Robots up to 2000 and 3000kg are available already and running at this moment in roto moulding.”

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Rising Sun – Guocai Zhu, Tom Chen and Sharon Zhu of Wenling Rising Sun Rotomolding Tech of China showed off their mould making prowess. Sharon also gave a presentation, ‘Advantages and Technological Reformation,’ in which it became clear that the company, which was one of the silver sponsors, manufactures a large number of moulds annually

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Bill Spenceley of Flexahopper of Canada, a leading roto moulder in North America, and Leise Donlan of the Association of Rotational Moulders of Australasia were in fine spirits at the show. Bill, a former director of ARMO, travels widely and suggested that travelling is one of the best means to learn about the roto industry … and improve things back at the factory

Mould with space frame with disperse flanges from Maus

The fines team were up to their usual tricks, extracting funds from well behaved citizens for all manner of ‘offences’ … and now, to make matters worse, the apprentice Grant Heroldt of Duys Rotomoulders is learning too quickly from the mentor, the wily Rod Cairns of JoJo. On this occasion, however, the guys excelled and raised over R60,000

Industry legends – Gary Lategan, Nick Aggett, Clive Robertson, Wayne and dad Jack Wiid, who have all spent more than 10 years on the ARMSA committee, were recognised for their unstinting work in the roto industry at the closing banquet – well done guys

Oliver Wandres of Maus of Germany, who is also a member of the global ARMO board, took a stand at the ARMO event this year (he was a presenter at the last two Rotation events). Maus is regarded as one of the top manufacturers of moulds for the roto sector internationally, and has also supplied some specialised moulds into SA OCT / NOV 2019 25

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ARMO2019

‘Three Musketeers’ focus on devil of wall thickness control

26 OCT / NOV 2019

Unusual presentation by fundis lays it all out

THE 2019 ARMO event included an unusual panel presentation by the so-called ‘Three Musketeers’ who looked at one of the most vexing problems in roto moulding: how to vary and manipulate wall thickness through machine, mould and material. This sort of thing doesn’t – actually never – happen with the other processes at play in the industry, but here we had guys who, admittedly all being suppliers to the roto industry, had several good suggestions. In roto, wall thickness is possibly more vital than in the other processes as excessive material loadings can easily render products unprofitable, while under loading can result in product failure – which can have the same or worse result (like long-term sales erosion). According to Ronny Ervik of Ultra Polymers, the number of roto moulders who achieve consistently good wall thickness control is, horrendously, less than 10 percent. Major financial losses can be incurred. He cited the example of pontoon production, which is popular in Scandanavia: if excess material of €6 is used per moulding, combined with €2 per unit in extended cycle time, loss of €8 (±R130) can result per moulding, which is not that disastrous … but if 500 units are being produced per year, that machine could result in losses of €4000 (R64,000) a year. So what looked like a profitable model, according to Ronny, can actually be costing you, a lot. Dhanu Patell of Reinhardt looked at how ineffective mould design and machine setting can similarly lead to material wastage. Anticipating this problem at the design stage is obviously the most logical way to solve the problem, but it’s not quite as simple as that, as the efficiency of the machine system plays a major role. Reinhardt is nothing if not totally

The Musketeers – The individuals concerned included Ronny Ervik of Ultra Polymers (Norway), Dhanu Patell of Reinhardt Teknik (India) and Oliver Wandres of Maus GmbH (Germany) each brought specific skills to the occasion The production of pontoons such as this, which are popular items in Scandavia, can result in major losses if effective wall thickness control is not practised; (at right) the core of the problem

ACD


Maus mould with heat fins and perforated shielding, strategies to assist heat retention or dissipation

Reihardt is busy with the development of a new-concept linear machine concept

dedicated to overcoming production problems on an on-going basis, referring to problems such as how sharper outer corners tend to thicken wall thickness and thinner inner corners tend to be thinned. Balancing the factors of rotation ratio, vectored air and temperature is an on-going challenge for the roto machine builder and Reinhardt believes, using its systems and effective mould design, and the use of an infrared camera, it can achieve consistent control, but a lot of other factors come into play ...

Reinhardt India has been building roto machines for close to three decades and, with on-going development, is now busy with the design of a linear roto machine concept. For Oliver Wandres of Maus of Germany, one of the world leaders in rotational mould manufacture, the problem of wall thickness control has many causes, all of which it anticipates and designs to counteract in every mould. Maus also looks at improving heating from the inside of the mould, and has come up with a number of new solutions. OCT / NOV 2019 27

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ARMO2019

Exhibitors put on a great show Bigger and better

THE exhibition at this year’s ARMSA global event (with the hosting of the ARMO conference) was considerably more extensive than at previous regional shows, and it has to be said the exhibitors put on a good show and business was conducted. Some of the visiting international exhibitors may even have shown

some of the local players that one really needs to front up on the stand and cut deals.

Monique and Shenton Botes of BTCAP were back at the ARMSA event, representing, among others, Axel mould releases from the USA. BTCAP offers both water and solventbased mould releases for all plastics. It also supplies various epoxy resins and the Jonnesway range of pneumatic tools of which they generously donated a tool box (of conventional non-power tools) which was auctioned off for the fund-raising for the Zululand Rhino Orphanage

28 OCT / NOV

The Sasol team included Nick Aggett, Joe Makhubela, Beverley Manikum, Natalie Sutton and Brian Sole

for Dhanu Patell, partners Shivinder Chawla and at ed ibit exh ia, Ind ardt in over 25 years at Reinh ardt machines have beARMO2019. The Reinh in South Africa, and Africa come very popular in ire and des m’s tea the to nks general in fact, tha o moulding problem’ ability to ‘solve any rot

Gary Burchell was on the Rotoquip stand, showing the range of injection moulded lids, connectors and fittings it supplies into the roto and rainwater harvesting sectors, mostly injection moulded at its plant in Springs Gaetano Donizetti of Perisco of Italy was joined on his stand by Martin Spencer of Unique Roto of England. Gaetano spent extra time in SA due to the commissioning of the Persico ‘Smart’ machine at Pioneer, in which respect he was assisted by Martin, who is a longtime consultant to the roto industry in Europe and SA

Showing true colours – Looking for all the world like a grand prix team, Andrew Robertson and Krzysztof Otrebski were on point duty on the ACD Rotoflo stand. They showed off a range of Rotoflo’s colour compounds


am Weaver, the André de Lange of Dre nder and roto pou com al teri ma ng Gaute a cooler box off d we powder miller, sho Braskem of m fro er ym pol a h wit made ™ polymers are made Brazil. The Green al (cellulose from renewable materi e) and colour can ar sug extracted from Weaver’s plant am Dre at d nde pou com g to André, the in Bashewa. Accordin “process and nt elle exc s wa result were similar ing uld mo conditions and LLDPE.” tic the syn al tion ven to con t.co.za mw rea w.d ww 072 737 1079 •

Michael Delidis of Orenda of Greece, a manufacturer of pulverising equipment and blades, would have won the best dressed competition easily

Konstantia Asteriadou of Lysis Technologies chatted about some of the UK-based manufacturer’s label-free graphics solutions with Spike Lemmer of RotoTank. Lysis’ main business is the production of printing inks, paints and coatings … as well as graphics for rotational, injection and blow moulding, supplied under the Tesoplas™ brand. www.tesoplas.com

Buoy marked with stencil and gloss roller from Lysis

The Matrix – Martin Coles and Grant Palling of Matrix Polymers in England returned to Africa with some interesting polymer solutions. Matrix is dedicated to the roto industry, literally supplying a complete range – from standard tank to ‘glow wire’ and conductive grades www.matrixpolymers.com

OCT / NOV 2019 29

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ROTONEWS

‘Rebounder’ wins ARMSA Product of the Year award It’s eight in a row for the indefatigable Pioneer

30 OCT / NOV 2019

THE Lisa Raleigh Rebounder T-bar exercise unit manufactured by Pioneer Plastics won this year’s ARMSA Product of the Year competition, making it the eighth year in a row in which the Rosslyn roto moulder has won the award. It has to be said that the opposition appears to have given up somewhat, given Pioneer’s dominance in this event, but let that not detract from the technical and design accomplishment here. Moulding holes in vessels such as this presents

make it easier to move the unit) which is problems with roto, so inserts were in PP; a keyed and tapered handle bar used. locator (to hold the handle in place); and The extent of the achievement lies a height-adjustable in the way the roto rebounder moulded base (waterThe system mounting hook to filled when in use, for is intended to keep the handle stabilisation) attaches to add value to locked onto the the steel handle, which rebounder. is telescopic to cater exercise studios A special venturi for users of different around the world was used in the heights. in a playful area where the Available in a yet serious wheel is affixed, to wide range of colour enhance heating combinations, the manner. and cooling – as system is intended to add value to exercise studios around the the complexity of the shape could have led to wall thickness distortions there. world in a playful yet serious manner. Features include clip-on rings on both the handle and base for resistance bands to be clipped onto; a roto moulded wheel (to

Lisa Raleigh puts the Rebounder through its paces herself. A huge variety of exercises can be performed on the device in a relatively small space, hence its attraction


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2019/10/03 10:53


WINNERS of Sasol Student Design

ARMO2019

Competition for ‘018 and ‘019

Young designers show expansive thinking, creativity SINCE the announcement of the winners of last year’s Sasol Student Design Competition was not made at Rotation 2018, the ARMO2019 event at Sun City in September turned out to be an awards double-header – and the students did not disappoint.

According to Nick Aggett of Sasol, who’s been coordinating the design events for over a decade, the standard was high again for both years. “Every year we are amazed by the students’ innovation,” said Nick at the prize

“Every year we are amazed by the students’ innovation.”

32 OCT / NOV 2019

2019 WINNERS The marine theme for this year threw the challenge wide open, and again the students rose to the occasion. The top trio this time were Azel Viljoen (UJ) with her ‘Immune Dune’ device (to retain beach sand) in third spot; Onkgopotse Mothibo (TUT) for her ‘Uncapped’ design to allow for safer jetty fishing in second; and the gold went to Denzil Bothma (TUT) for his ‘Beach Muncher,’ a system with roller and scoop/ skip for cleaning beaches

giving event on 17 September. Students from the Tshwane University of Technolgy (TUT) and the University of Johannesburg (UJ) participated. The brief for the 2018 competition was to design a device that could be roto moulded and be used in sport and recreation activities. For 2019 the challenge was to design a product which could be used in applications

2018 WINNERS Grant Tinney (UJ) won bronze for his design of a rowing boat stand; Rayna Haselum (TUT) and Michelle Rossouw (UJ) tied in second place with their designs of a device for transporting gliders and for stacking hockey sticks/ storing balls, respectively; while Gregory Havenga (UJ) took gold with his ‘Scull Assist’ design, to allow kayakers and rowers to stabilise their craft when getting in or out (it attaches to a jetty) – in short, ingenuity was very evident


A large part of the thanks for encouraging the students to excel at the design challenge is due to the Design Faculty lecturers, Hein Dubery of TUT and Antonio Marin of UJ. Here they are flanked by Nick Aggett and Chris Sole of Sasol, sponsor of the competition

on beaches, whether for leisure, environmental care or other. It has to be said that, for both years, the students came up with a whirlwind of

It has to be said that, for both years, the students came up with a whirlwind of ideas!

ideas, not to mention catchy names – ‘Wave Ezee,’ ‘Beach Muncher’ and ‘Swifty Swirly’ being just some of them.

OCT / NOV 2019 33

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2019/09/13 10:46


NEWS

Mould entering the oven

Fanie Ferreira and Lawrence Bernard, co-owners of the Plastiflo water tank business, flank Willy Nelson of Waspquip, the machine supplier

Clear control system makes set-up and diagnosis of problems straightforward

High quality surface finish is a feature of the Plastiflo tanks

Roto moulder Plastiflo gets India RotoPlast machine ticks all boxes A NEW manufacturer of roto moulded water tanks, Plastiflo, has gone into operation at Jeffreys Bay on the Garden Route. The venture by local farmerbusinessman Fanie Ferreira literally came about when he noticed that there wasn’t a tank manufacturer in the region and saw a need in the market. With roto moulded tanks, being in the proximity of customers is the name of the game – since transport cost can become a major factor on the balance sheet. As it is, J Bay is centrally located to the Garden Route and Great Karoo areas. Working with machine supplier Willy Nelson of Waspquip of Port Elizabeth, Ferreira decided on a system from India RotoPlast of Gujarat (India’s most westerly state). Installation of the machine commenced in January and the first tanks were manufactured in March. Although Ferreira is new to the roto game, Plastiflo has been involved in the fabrication of troughs for water and feeding of livestock since 1996 as well as the injection moulding caps and components, in the process building up the skills for the latest venture. “We are farmers, first and foremost, and then manufacturers. Therefore we know the importance of delivering robust and durable products to a farming community who expect nothing less,” said Ferreira. 34

ROTO NEWS.indd 34

OCT / NOV 2019

It came as no surprise to the Plastiflo MD that teething problems were encountered during the commissioning phase, but these were rapidly resolved with the help of Waspquip and India RotoPlast. An engineer from India RotoPlast assisted during the setup phase too. Plastiflo is currently manufacturing five tank sizes – 500, 1000, 2000, 3000 and 5000 litres – and investigating the potential to make a 1000-litre ‘slimline’ tank. The moulds were also supplied by India RotoPlast, with stainless steel being used, which was necessary due to the factory’s close proximity to the sea (a few kilometres away). The moulds have been polished to a high degree, resulting in exceptional quality surface finish being achieved and giving the Plastiflo tanks a somewhat unique appearance. “They don’t look like the standard water tanks that South Africans are used to seeing,” said one observer. ‘Food grade’ grade material is used (recycled material is not used) and the tanks are also safe for the storage of chemicals. Plastiflo mills its own roto material powders on site (the factory is actually closer to Humansdorp).

The RotoPlast machine is cycling consistently and Ferreira says “we could find a way to speed it up but we don’t want to compromise the quality”. Production is managed by Lawrence Bernard, who is also co-owner of the water tank business. The company also has a dedicated sales person who, Ferreira says, is doing a fantastic job. It is also involved in a collaboration with a specialist tank installation business. Incidently, roto moulding is also new to Willy Nelson of Waspquip, the machine supplier. He had been servicing Plastiflo’s other machines for some years and only decided to get involved with the roto work when Plastiflo inquired. “I went to India and spent time visiting several roto moulding machine manufacturers and by process of elimination formed a partnership with India RotoPlast,” said Nelson. “The machines are robust, and offer value for money. All elements are decent quality, and the electric drivers are very good.” The moulds for the feeding troughs are made by Plastiflo in a separate workshop.

‘We know the importance of delivering robust and durable products to a farming community’

www.plastiflo.co.za

2019/10/06 11:41


The moulds, also from India RotoPlast, are manufactured in stainless steel and show an impressive level of polishing, resulting in a high quality surface finish for the tanks. Going stainless was also necessary to reduce corrosion as the factory is relatively close to the ocean

rolling in J Bay

The new India RotoPlast machine went into operation at Plastiflo in Jeffreys’ Bay earlier this year

A dedicated factory was built for the purpose

OCT / NOV 2019

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2019/10/06 11:42


NEWS

JoJo Tanks acquires

homegrown brand Calcamite JoJo continues its transformation into a water solutions company LEADING Southern African roto moulder and water tank producer JoJo Tanks has acquired Calcamite, specialists in wastewater and sanitation. With this latest acquisition, JoJo Tanks continues its transformation into a water solutions company. Following on from its recent expansion into pumps and filtration products, this recently concluded deal provides JoJo with the capability to provide solutions into the growing domestic waste water management space. “We are focused on growing the business beyond water storage, into

a full water solutions company,” says JoJo MD Grant Neser. “We started slowly by supplying domestic pressure pumps to the market some years back. Earlier this year, we launched our filtration range and this acquisition provides us with a strong position in the domestic waste water sector.” JoJo purchased 100% of the shares in Calcamite Operating Business and the Calcamite Property Holding Company, therefore the rights to ‘everything Calcamite’, including all intellectual property and all subsidiaries operating in Africa and worldwide.

John Telford remains fully engaged as CEO of Calcamite and is now also a management shareholder in JoJo. “We believe that domestic waste water management is a growing industry in Southern Africa and Calcamite is well positioned to participate in this growth,” said Neser. “Water and sanitation are invariable linked, and that is why Calcamite is a perfect fit for JoJo,” explains Neser. “Without suitable waste water management we cannot have quality water, and without quality water we cannot have good sanitation.

Matt Rubber Mouldings celebrates Sole source of production for many of the products it manufactures CELEBRATING 35 years of operation, Matt Rubber Mouldings has seen considerable development and growth and the sole source of production for many of the products it manufactures. Making use of its extensive production facilities in Gauteng’s West Rand area, the company relies on its technical expertise and exclusive techniques to manufacturer, distribute and sell rubber and plastic mouldings and related products like polyurethanes and silicone. The company has its own mixing facilities and supplies a diverse range of products to a widely distributed customer base in the automotive, mining, plumbing, industrial and engineering, food and electrical industries. Customers include Professional Lawn Equipment, Pennyware Distributors, Rubber & Allied, Thomas Pipe Products

and many more. Products and moulds are manufactured according to a customer’s specific design and specifications. Matt Rubber Mouldings is managed by Martin Kotze and Marius Mostert who

Partners, Marius Mostert and Martin Kotze with products manufactured at Matt Rubber Mouldings. Marius is holding a ‘Yikskei baton’ and Martin a shock absorber type damper that he personally took through four days of trials to achieve its ultimate performance level 36

ROTO NEWS.indd 36

OCT / NOV 2019

2019/10/06 12:16


JoJo Tanks’ MD Grant Neser

“There is a real and urgent need for practical, fit-for-purpose, on-site waste water and sanitation solutions in our country, and this is where Calcamite is an industry leader,” Neser adds. Just like JoJo, Calcamite is an entrepreneurial business with a long history (established in 1967) and is also authentically African. Calcamite has a sound reputation in the waste water sector, with technical know-how developed over many years of practical, hands-on participation in the industry, which was crucial to the deal. Both

companies also share similar values – both are committed to the manufacture and supply of products and solutions that meet society’s needs. Calcamite, established in 1967, has evolved into a vertically integrated, full-turn key on-site, sanitation solution provider. “Our Biomite on-site waste water treatment system and our ability to design, manufacture, supply, install and maintain these systems, is what sets us apart in the industry,” says John Telford, CEO of Calcamite. “In our 52 years of

35 years! bought the company in October 2017. Both have vast experience and expertise in the rubber industry, gained over many years. Martin Kotze has 22 years’ experience in the industry, starting in 1997 at BTR as a maintenance fitter. He then moved to Dunlop Rubber Mouldings technical and sales departments where he spent eight years before the company was bought. Martin has also successfully completed various diplomas and certificates in polymer technologies and science. Marius Mostert has 14 years’ experience in the industry, starting as a qualified toolmaker 2007. He started his own business, M&M Mouldings, supplying moulds and rubber products to Hudson Rubber and Rubberite. Marius also worked at Dunlop Rubber Mouldings in the toolroom, designing and manufacturing plastic and rubber moulds. “Our aim is to develop and maintain a healthy

existence, we have notched up many firsts. We are the first company in the world to receive an Agrément certificate for an on-site sanitation system. In addition, we are currently the only manufacturer to hold SABS certification for our range of septic tanks.” The companies will continue to trade and operate as separate entities, but complimentary and synergistic opportunities will be pursued at management and corporate levels to strengthen their respective positions in the domestic water solutions market.

www.calcamite.co.za

Partners, Marius Mostert and Martin Kotze with products manufactured at Matt Rubber Mouldings. Marius is holding a ‘Yikskei baton’ and Martin a shock absorber type damper that he personally took through four days of trials to achieve its ultimate performance level

relationship with customers and suppliers for mutual benefit,” says Kotze. “We achieve this through honesty, integrity and a willingness to assist at all times, to uplift the staff and community and always looking at ways to improve the company, process and working conditions. With us the customer is always first,” adds Mostert. Matt Rubber Mouldings is also involved in charity events and fundraisers in the West Rand. www.rema-tiptop.co.za

ROTO NEWS.indd 37

www.jojo.co.za

OCT / NOV 2019

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2019/10/06 12:16


PIPES XII

Growth, opportunity and SA pipe market grew by 22% over the past seven years THIS year’s edition of the SAPPMA Pipes conference – Pipes XII – attracted more than 180 delegates, 11 local and four international presenters, 15 exhibitors and nine sponsors who gathered to learn about best-practice designs and applications, share ideas and

plastic pipe

discuss the latest innovations in so far as plastic pipe manufacturing and installations are concerned.

‘Economic recovery beckons if the NDP is implemented’ in which he unpacked the challenges and obstacles to growth, but also the exciting opportunities that await South Africa over the next 12-18 months.

Supported by Rare Plastics, Sun Ace, Sizabantu Piping Systems, NSF International and Pipeflo, Pipes XII provided a platform for South African pipe experts to present and International speakers on the first also drew international day included Albert Lueghamer Never of Agru of Austria, Antonie participation from as far been in a better Walter of GF Piping afield as Germany, Systems of France and position to grow Austria and the Middle Stefan Schiesser of East. the economy at Borealis of Denmark; Economist and seen here with local significantly higher speakers Renier Snymn scenario analyst Dr rates than before – of Sun Ace, Kirtida Bhana Roelof Botha delivered of PlasticsSA and Ian Dr Roelof an optimistic, witty Venter of SAPPMA, together and honest opening SAPPMA manager Louise Botha Muller (second from right) keynote address entitled

Dr Roelff Botha (right) was welcomed back at the Pipes event, held in August, by Jan Venter and he certainly did point out some fundamentally positive signs in the local economy

Anders Nystrand of Uponor of Finland gave an interesting ‘Weholite Journey’ presentation, Mike Smart outlined recent PVC-O developments; Jacques van Eck of Avesco explained how easily a pipe project can go wrong and yet how simple it is to engage an expert consultant to ensure a quality outcome; and Mark Berry of Safripol hosted the session 38

OCT / NOV 2019

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2019/10/06 12:21


possibilities for

industry

Whilst poor economic leadership over the last 10 years has left South Africa reeling and resulted in GDP losses of at least R2.5 trillion and R653-billion foregone in tax revenue. Dr Botha said that it was not all doom and gloom. He shared good news of real growth reported in retail and mineral sales, short-term insurance premiums, household and disposable income. “Every problem we have (in South Africa today) can be solved with the right policies and right skills,” he commented, highlighting the need for more infrastructure and better governance. “We are starting to see various green shoots as the positive effect of President Ramaphosa’s leadership. If this continues we can be confident of the future. We have never been in a better position to grow the economy at significantly higher rates than ever before!” Bigger markets and growing demand “It is almost impossible to imagine our Going trenchless – Marco Camarda of Trenchless Technologies and Alister Goyns of Pipes cc are among the proponents of trenchless technologies and have managed some tricky installations. In a project referred to by Marco, the trenchless method was used to replace a 1,3km asbestos cement pipeline at the Temba water purification plant in Gauteng. Using horizontal directional drilling (HDD), the team succeeded in reaming the line and inserting an 800mm HD pipe. The drilling proceeded at a rate of a metre every three minutes

Vryburg pipeline – Laying pipe for conveying water, or anything for that matter, is challenging … it’s very difficult to make changes once the thing is in. The experience of consultant Onno Fortuin (left) in developing a new sewer outfall system for Vryburg was, exactly that, challenging. Besides the fact that the very flat topography made it difficult to use gradient to boost flow, a part of the problem was conflicting assessments of plastic pipe. Substantial earthworks were required

modern life without use of plastics. This versatile material has become deeply embedded in our everyday lifestyle. Although the use of plastic packaging has come under harsh criticism by environmentalists and the public alike over the past year, it is important to recognise that not all plastic is bad for the environment. It is an extremely useful product that is used with great success in pipelines, appliances, cables, computers etc to reduce manufacturing costs, improve performance and reduce mankind’s impact on the environment,” said Jan Venter, chief executive officer of SAPPMA, during his opening speech. Other presentations showed how research and development to improve polymers and processing equipment are dynamic and ongoing throughout the world. This has resulted in the plastic pipe industry enjoying a dominant footprint in most countries. In South Africa, the market grew by 22% over the past seven years to deliver the infrastructure needed to support a growing population. Similarly, the development of new markets and applications were unpacked by the various presenters who focussed on outstanding

properties of modern plastic pipes, such as flexibility, toughness, corrosion resistance, the growing demand for large diameter pipelines (with pressure pipe now up to 3m diameter) as well as various other exciting technological advancements and applications. Feedback from delegates was positive “This was my first attendance at a Pipes conference and I thoroughly enjoyed the wide scope of presentations that were delivered. It was interesting to hear about the experiences from the endusers (engineers and consultants),” said Giel van Jaarsveld of Sasol. Kudzai Jinjika of Proplastics of Zimbabwe said “the conference was exciting and informative. The excitement was maintained since the very beginning and the food and services were exquisite. I really wished it could be longer than two days!” “One of the best conferences I have attended, thank you!” said Japie Botha of Pro-Plan Consulting Engineers. International presenter Stefan Schiesser of Borealis said it “was a very open and fair conference with excellent possibilities for discussions in the breaks and at the end of the days”. >> OCT / NOV 2019

SAPPMA PIPES CONFERENCE.indd 39

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PIPES XII Growth, opportunity and possibilities for plastic pipe industry >> Local presenter Onno Fortuin said “the interaction between industry, suppliers, engineers and planners are critical for the way forward”. Looking ahead “Modern plastic pipe materials can be relied upon to provide cost effective pumping solutions, exceptional health standards and previously unheard of service lives. For this reason, it is of great importance to host an annual industry-specific event where we can share the latest technical information about design, manufacture, maintenance, evaluation, testing procedures and standards,” said Venter. “In an era where taking shortcuts and cutting corners have become the norm, SAPPMA plays an instrumental role in the development, advancement and maintenance of correct standards and performance of piping systems. Together with our members, we will continue to be the flagbearers for maintaining excellent standards and quality in a very important industry through the commissioning of reliable and knowledgeable consultants, pipe manufacturers and installers,” he concluded.

Pipes XII AN EXHIBITION was held in parallel with the SAPPMA Pipes XII conference in Midrand and it’s a fair bet to say you would have been able to get anything you sought in terms of plastic pipe, fittings and installation in Southern Africa right there, and all was cordial on the two days of the event as the rival suppliers went about their business. Agru of Austria was the winner of the ‘Best Exhibitor’ competition, with Pipeflo, the Koedoesport HDPE pipe manufacturer, being the runner-up and and Zerma SA, the supplier of size reduction machinery, in third spot, but all the stands were of a high standard! Alois Rieder on the Agru stand spent a part of his earlier career in SA before moving to Austria

www.sappma.co.za

Albert Lueghamer of Agru received the best exhibition stand award from Jan Venter Renier Snyman of Sun Ace, Leanette Moodley and Thando Madlala of Associated Additives Delyce Ririe of IMCD and Stefan Schiesser of Borealis, whose materials IMCD supplies locally

The Zerma stand was adjudged as the bronze winner, with Chantal Shaw and Bart Schurink there. Bart has recently signed on at Zerma, welcome 40

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exhibition winners Michael Wilson and John Molefe on the Sizabantu stand Photos: Lowrie Sharp

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Two happy ladies, Vanessa Stander and Ronel Liebenberg of bsi. The bsi Kitemark™ standard applies to virtually every household item (including HDPE and PVC pipes and fittings)

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PIPES XII

Photos: Lowrie Sharp

Pipes XII exhibition winners

Rudi Coetzee, Lesley Harilaou, Vino Naidoo and Jonathan Sizer on the Rare stand Jean Emmenis and Fonnie Meek on the Plasti-Tech stand

Monique Holtzhausen (AIM Marketing) and Diane Blumberg and Monya Vermaak from Plastics/SA on the Plastics/SA stand

Terry Coetzer on the Sun Ace stand 42

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www.sappma.co.za

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FEATURE

PIPE MATTERS

Are the ‘winds of change’ By MIKE SMART, Pr. Eng., B.Sc. (Hons) Civ. Eng., MSAICE

IN about 2000, the same year the PPPFA (Preferential Procurement Policy Framework Act) 2000 (Act No. 5 of 2000) was promulgated, South Africa accepted a gift of many tons of grey PVC pressure pipes (SA’s colour code is blue) from the Government of the Peoples Republic of China. Pipes that should have been supplied by our local manufacturers, who support South Africa, employ our people, pay their taxes, develop local skills, invest in South Africa, and support other local companies. This was a shortsighted and extremely harmful decision that must have been made with little or no consideration for the consequences. Three Chinese manufacturers were appointed by their government to supply the pipes, many of which were found to be non-conforming when tested in South Africa, including inter alia, pressure, joints and gelation. In fact, the quality of pipes from one supplier was so bad they were excluded by the Chinese Government, from subsequent deliveries. The local PVC pipe manufacturers were incensed, made urgent representations to the South African government to terminate the supply as a matter of extreme urgency to limit the damage to the local industry, and associated jobs.

About ten years later the government’s document that, “revised regulations to the PPPFA empower the DTI to designate certain industries that are of ‘critical importance’ for local manufacture by organs of state and public enterprises”, was published. It was exactly what the South African thermoplastic pipe industry had wanted for years. The Application Document’s questions included, inter alia, “Significance of public procurement for the industry”, and “Imports”, and “Industry multipliers”, and “Competition and pricing”, and “Availability and security of supply”, and “Local content”, and many others. In fact, all the things the local thermoplastic pipe industry had been bringing to government’s attention without success for years. It was ‘just what the doctor ordered’ for the industry – or so we thought. In 2012, I submitted a comprehensive 19-page document that addressed each of the requirement points in the government’s “Industry Profile Template for Designation in Terms of the PPPFA”. On completion, we considered it so important we didn’t risk delivery by any means other than personally taking and lodging it with the requisite person – and we waited. Subsequent enquires confirmed: yes, the document had been received; yes, it was adequate; no, there were no questions; yes, it was being dealt with; and yes, we

“Government cannot give to anybody anything it hasn’t already taken from somebody else.”

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would be informed in due course. Five years later, at a meeting with the DTI, we were advised that the original process had been aborted because of ‘strong objections’ from the accountants of the DTI, based on their concerns that designation would lead to ‘price fixing’ at the expense of the state. Methinks their concerns were somewhat misplaced in light of revelations at the Zondo Commission of Enquiry. Such an allegation against an industry as competitive as thermoplastic pipe manufacturing is, is so misplaced as to border on the ludicrous. It only served to illustrate that the submitted documents could not have been studied properly, because they clearly proved the highly competitive nature of the industry. However, we were advised that the matter was under review and designation was being reconsidered – and we waited. The South African public entities that procure thermoplastic piping systems include government, SOEs, provincial governments, water boards, metropoles, and municipalities. Moreover, despite the population increasing, pipeline infrastructure construction is falling behind (see the April/May 2019 issue). The pipeline infrastructure backlog increases each day and yet the problem doesn’t receive the attention it urgently demands – the ‘can gets kicked down the road’. The duty of a municipal engineer can be succinctly defined as: “To provide necessary services to the community” – not complicated.

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blowing through SA? to R25.2-billion in 2018, down 15% – cause for celebration? Furthermore, there is cause for celebration regarding the PPPFA. On 16 August, National Treasury Designated Sectors Circular Number 1 of 2019/2020 designated Plastic Pipes (PVC; HDPE; PP; GRP) for local production and content. Are the ‘winds of change’ blowing through our land?

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government all his life – a long time. He advised that a ‘rule of thumb’ for municipal expenditure was about one-third to salaries and wages, about one-third to maintenance, and about one-third to new projects. Currently about 85% goes to salaries and wages! If you want to see where the service delivery is, go and look at the municipal offices. A recent report states South Africa municipal ‘irregular spending’ reduced from R29.7-billion in 2017

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Therefore, if the necessary services are not being provided, the municipal engineers are not doing their duty – simple. Which begs the question, “Why not?” If you canvas the question with municipal engineers, they advise there are insufficient, or no, funds. But if South Africa is an increasingly urbanising population, which it is, the municipal revenues must be increasing thereby providing the necessary funds. An old friend has been in local

2019/09/13 12:27 11:17 2019/10/06


RUBBER NEWS Belts are up – Rema TipTopDunlop managing director Steve Almond is dwarfed by these massive rubber belt reels manufactured by the company in Benoni. The belts are destined for customers across Africa, in this case Guinea in West Africa. Rema TipTop has expanded its supply of these belts to customers outside of SA, mainly for use in mines, to the point where sales outside of SA recently exceeded SA sales for the first time

Sales into Africa climb at Rema TipTop-Dunlop Expertise of rubber sector vet Almond helps turnaround in Benoni EXPERIENCE counts for a huge amount and that is especially the case in the relatively sedate rubber sector. Often rubber products look very similar, tend to be uniformly black and a little boring … but the performance criteria are severe and – if the compound is not properly prepared or product construction out of sync – wear and tear can leave items such as belts and tyres ragged virtually overnight. That’s where rubber sector veteran Steve Almond has proved very useful at Rema TipTop in Benoni. Having more than three decades experience in rubber work (he was previously at Specialised Rubber and Hitec Rubber), Steve obviously knows a bit about rubber compound and – ditto – the manufacture of rubber products. In the case of Rema’s products, several include reinforcement in the form of steel or other fibre, meaning that the ‘construction’ of the products often takes place in extended machine layouts, in some cases of over 50 metres and more. Steve has been putting his expertise to good use over the last few years, virtually crisscrossing Africa to sell Rema’s belts and lining (surface protection) products. This hasn’t been an easy undertaking, but 46

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Steve has triumphed, at least as far as sales figures are concerned. Part of the sales pitch, like it is for most of us, is convincing the customer that the cheaper alternative is not necessarily preferable and if anything can lead to considerable additional costs, and system down time. Besides the neighbouring states, Steve has also been to such seldom visited spots as Guinea (there are three in Africa: Guinea Bissau, Equatorial Guinea and Guinea itself) and Eritrea. And, guess what, he found there’s far more going on than expected. The outcome of these excursions has been increased demand from African customers, to the point where Rema’s sales into Africa exceeded sales into SA for the first time recently. However, Rema has simultaneously completed a number of major South African contracts, including the lining of deep sulphurisation power plants such as at the Kusile power station, which have been their biggest projects of late. For Steve, applying his experience has had a knock-on effect for the Rema TipTop business in Lincoln Road, Benoni, one of the largest sites on the East Rand where rubber belt and product manufacture has

One of Steve Almond’s most important objectives at Rema was to identify capable younger individuals for management roles and one of those who has risen to the challenge is Brett Beetge, who was recently appointed as a director. Brett, 31, is a qualified CA but is now enjoying the hands-on work in the rubber sector

been underway for 90 years – that’s right, since 1929. Rema Tip Top Africa, a full subsidiary of Rema TipTop AG of Germany, operates subsidiary businesses in Ghana, Madagascar, Mozambique, Zambia and Zimbabwe. www.rema-tiptop.co.za

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RPM under new ownership as Tozer, Supasar take helm Long-established Cape rubber moulder gets new lease on life RUBBER Products & Mouldings, the specialised Cape custom rubber moulding business, is under new ownership with Wayne Tozer and Sue Supasar having taking the helm in what promises to be an exciting new phase for the company. RPM, one of the oldest rubber moulding businesses in South Africa, having been established in 1954 by Barry Hollis, has relied on very stable management over the ensuing six decades to the point where its equipment is somewhat dated yet very well maintained and, most relevantly, it has a committed core of employees. With Hollis aging, the company had been on the market for most of the past 10 years and it was Tozer, who left his previous employer in early-2018, keen to go solo, who made an offer towards the end of last year, which was rejected. But the man saw potential in RPM and made a second bid shortly earlier this year. This time Hollis accepted and the details were concluded, including the purchase of the property in Voortrekker Road, Maitland. Tozer, who is a chartered accountant, had barely taken over when he realized he’d needed assistance in the production management area when, unexpectedly, he was approached by former colleague Supasar. After brief analysis, Tozer and Supasar agreed on terms and a new phase for RPM commenced with immediate effect. Both the new directors still reside in KZN, but such is the impetus of the venture that that’s but a minor detail at this stage. Supasar has over 26 years’ experience in the rubber industry and has been the recipient of a number of accolades, including that of managing the process leading to her previous employer winning a Productivity Workplace Challenge programme. Tozer has been involved in the rubber game for over 20 years and focusses on business financial management and has consistently focused on strategic growth. “The skill set we have are differing but complimentary. We decided to remain in the rubber industry as we have quite considerable experience between us,” said Supasar.

Wayne Tozer and Sue Supasar, new co-owners of Rubber Products & Mouldings, are happy that the Cape Town business has such solid foundations, having been in operation since 1954, and are mapping out interesting developments for it

Tozer’s philosophy is that “a successful partnership is only successful if the partnership is equal and transparent”. The new directors have demonstrated their commitment to sustaining and growing the business, which was very important to the late Barry Hollis, who was passionate about the business and its people. One of the few companies to offer specialized custom rubber moulding, RPM also operates a unique retail division at adjacent premises. Objectives Significant cost savings have already been achieved without any structural changes, “That’s the joys of partnering with a bean counter,” said Supasar. Other objectives are emerging for RPM, including its appointment to supply certain rubber compound grades from global leader Hexpol. “We are excited to have partnered with Hexpol Compounding (UK) to supply the Sub-Saharan African market with rubber compounds for the roller and lining markets. This is a huge accomplishment as it gives RPM the competitive edge in supplying international technology into the roller and linings industries in SubSaharan Africa,” said Supasar. “RPM has truly transformed in the spirit of BBBEE and believes in ethical BBBEE transformation. We have transformed from non-compliant BBBEE status to Level 2 BBBEE status with 51% black female-owned,” said Tozer. Growth in the manufacturing division is seen as a priority. Further planned expansion is anticipated to commence in the first quarter 2020. “We are very excited about the projects we are working on. In the medium term we envisage RPM to become a national player,” he added. www.rpm.co.za OCT / NOV 2019

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ENVIRO Transpaco says impact of plastics on environment is misunderstood

TRANSPACO is holding discussions with the government, shopping mall owners, retailers and environmental bodies to dispel what it describes as misconceptions about the impact of plastics on the environment. The JSE-listed plastics and packaging company said there was an unfavourable sentiment towards retail plastic bags. Transpaco manufactures, distributes and recycles plastic and paper packaging products for sectors including retail, industrial, agriculture, mining, pharmaceutical and automotive. The company said it had started manufacturing retail shopping bags produced from compostable materials as an alternative. It is also exploring the viability of establishing a retail bag production facility to manufacture bags from two alternative materials. This comes as the government is considering a new policy to combat the use of single-use plastics. Environment, Forestry And Fisheries Minister Barbara Creecy, said in July the government needed to respond urgently to improve the management of plastic waste. Creecy said the government had started a review of the effectiveness of policies related to the management of plastic waste. The review is likely to be concluded within the 2019 financial year.

The WasteShark™ was put through its paces in Hout Bay harbour on the Cape peninsula in June, where Douw Steyn of PlasticsSA met up with Richard Hardiman of RanMarine

‘Waste Shark’

tested for harbour

Drone technology company builds ‘aquadrones’ to clear water surfaces RANMARINE Technology, a drone technology company from the Netherlands, specialises in remote controlled and autonomous drones called ‘Sharks that operate on water, extracting unwanted material and gathering data about the marine environment. RanMarine’s WasteShark™, modelled on Earth’s biggest fish, the whale shark, will ‘eat’ plastics and other floating litter; extract alien and pest vegetation; and

can detect chemicals in the water. RanMarine recently invited Douw Steyn, PlasticsSA’s sustainability director, to view the system in an ‘ocean trial’ in Hout Bay harbour on the Cape peninsula. The WasteShark is designed for both human-operated and autonomous operation, and with zero greenhouse emissions. It can operate for a 16-hour day by remote controll or on a plotted course, can move forward or in reverse,

Biodegradable energy

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Invention can alleviate the problem and is a step towards a more sustainable solution

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A 100% edible and biodegradable energy gel package, named Gone, which breaks down in a matter of days with the help of rain and insects

TRAIL runners are generally pretty good about minimising the use of disposable plastics. A lot of them run with soft flasks, hydration packs and collapsible, reusable silicon cups – all of which help to cut down on single-use plastics. Well-organised trail running races rarely have disposable cups at checkpoints and water stations, and competitors are encouraged to bring their own cutlery for food at finish lines. Unfortunately, they’re less good about gels and bars. As much as they try to clean up after themselves, a number of those plastic-coated foil wrappers inevitably find their way on to the sides of trails and into bushes, posing not just an eyesore but also an environmental hazard. Lizzie Wright, an industrial designer, hopes her invention can alleviate the problem and represent a step towards a more sustainable solution. She has developed a 100% edible and biodegradable energy gel package, named Gone, which breaks down in a matter of days with the help of rain and insects. The retail packaging that the gel packets come in is also completely compostable, made from paperboard and finished with laser-etched bioplastic.

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Terrazzo from recycled plastics

aquadrone

clean-ups, and more has an unladen weight of 39kg and a carrying capacity of 200 litres. It can also be fitted with additional devices, such as sensors for temperature, pH, conductivity, oxidation-reduction potential and depth … and then send data back to ‘central command’. Steyn said he thought the system could be too sophisticated for the local situation, and could not be used offshore around the SA coast due to

gel packets

frequently rough conditions. However, he congratulated RanMarine on the progress made so far. The WasteShark is still in the development phase and the process could yet result in important further progress in the fight to curb marine plastics litter, added Steyn. RanMarine also supplies the DataShark™, a learning machine continually collecting data about the marine environment. www.ranmarine.io

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Terrazzo is a composite material poured in place or precast, which is used for floor and wall treatments

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Eventually, she settled on a thin, flexible, and translucent material, which she developed from her art studio at school. Then she came up with the actual design of the package, and worked to make their appearances “regular and perfect each time”.. One challenge Wright has faced with her biodegradable energy gel packets is their short shelf lives relative to the conventional plastic-coated foil packets. This may be a disadvantage, Wright explained, but it actually encourages more conscious consumption habits. She also recognises that bioplastics aren’t a magic bullet to our plastic crisis. For example, many compostable plastics still have to be treated and disposed of properly. And the growing popularity of bioplastics may in turn perpetuate a disposable culture. A convenient, well-designed alternative, like her biodegradable Gone packaging, offers users a feasible choice, she explained. “Obviously, bioplastic is not the perfect solution,” Wright added. “But it’s a renewable solution, which is better.” www.iamlizziewright.com/gone

FOR decades, terrazzo has been used as a durable flooring material in construction. Now, 23-year old Ugandan, Anthony Kasumba, recycles plastic waste into terrazzo, Dorothy Nakaweesi writes in The Daily Mirror. Terrazzo is a composite material poured in place or precast, which is used for floor and wall treatments. It consists of chips of marble, quartz, granite, glass or other suitable material, poured with a cementitious binder, polymeric or a combination of both. Anthony, an innovator from SINA (Social Innovation Academy) in the Mpigi District in central Uganda, is the brain behind terrazzo from fused polythene bags and plastics waste. SINA tackles failing education and resulting unemployment in Uganda through creating self-organised and responsible learning spaces, where disadvantaged youth unleash their potential for positive change as social entrepreneurs. Kasumba, a Form Six dropout enrolled at SINA early this year. To help develop his creation, Kasumba visited a Coca Cola recycling plant. While there he realized that during the process of cutting, sieving and packing the caps, smaller plastic particles were created which were usually dumped. Kasumba realized that he could use these small particles as as a raw material in terrazzo production. Besides the plastic particles, Kasumba also uses plastic bags cut into small particles as raw material. The plastic scrap collected is soaked in water for a few days to allow the plastics to separate from other residues, such as paper. The remaining plastic is mixed with white cement and then moulded into block-like slabs. Ideally, Kasumba mixes 70% of the small plastic particles with white cement. The block-like slabs ground and polished to make smooth tile-like structures – terrazzo plates – that can be used in constructing floors.

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ENVIRO

Researcher:

If you manufactured the 350 million tons of plastics produced every year completely from bio-based materials, you would need about 5% of the available acreage

Bio-based materials

can help with ‘bad image’ of plastics A major research area is the development of so-called ‘drop-ins’

By Plastics News Europe

BIOPLASTICS could potentially help restore the ‘bad image’ of plastics, says Hans-Josef Endres, head of IKK Institute for Plastics and Circular Economy at Leibniz University of Hanover.

y

Q: Plastics have a bad image. Can bioplastics contribute to changing attitudes? Endres: Bioplastics can have an impact on the image because they have advantages regarding the raw material as well as their disposal. Plastics have their bad image not only because they are related to petrochemistry, but also on account of their longevity. In truth, the situation of bioplastics is no better. In the public, the negative image of petrol-based plastics is often transferred to bioplastics, although they have advantages as they are compostable and also recyclable. Consumers do not differentiate. Q: Bio-based plastics are criticized because they use up food resources, correct? Endres: This criticism is too sweeping. The greenhouse effect also consumes acreage and renewable raw materials are also used in the energy sector. When we talk about raw materials for bio-based plastics we do not only mean those that are the basis for food, but also cotton, rubber or linoleum, as well as agricultural waste materials. If you manufactured the 350 million tons of plastics produced every year completely from bio-based materials, you would need about 5% of the available acreage. 50

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Q: Why should you produce bio-based plastics if it is not biodegradable? Endres: One might also ask why produce bio-based plastics if you can make them petrochemically? The benefit is a reduction in CO2. Every plastic material is disposed of at the end of its useful life – by burning or, in case of many bio plastics, by composting. Bio-based plastics are climate-neutral. In addition, the demand for plastics is rising. Soon we will no longer need 5 but perhaps 10% of the crude oil reserves to produce plastics. For this reason, the mineral oil industry could more easily do without the plastics industry as a customer than vice versa; at present plastics still need petrochemical raw materials. Q: What is the current focus in the research of bioplastics? Endres: A major research area is the development of so-called dropins. These are bio-based plastics which are identical in structure with their petrochemical counterparts, for example, polyethylene or PET made from bio-alcohol. Technically they offer the same properties as conventional plastics but ecologically they are better as they are bio-based, that means renewable. Q: Is recycling a problem for bioplastics? Endres: Bioplastics can also be separated in the waste stream, recycled and made into new products. If they are composted or even burned, it is still natural recycling of the carbon by means of photosynthesis. When

we recycle petrochemical plastics, the carbon is recycled technically. Drop-ins can also be recycled easily together with their petrochemical counterparts. Apart from this we have novel bioplastics, such as PLA. PLA must – just like any other plastics material – be separated from the waste stream. That means recyclability depends on the amount of available material. PLA is easily identifiably in the waste stream; it can be recycled, but due to the small amount it is currently not worthwhile to include a special sorting stage for PLA. Q: What are the advantages of biocomposites over other material composites? Endres: The case of carbon fibres shows the dilemma of composite materials. Carbon fibre materials have very good performance characteristics, but it is difficult to dispose of them. In addition, the production of carbon fibres is very energy intensive. A car made of CFC components weighs clearly less and consequently consumes less fuel or energy. But the car needs to drive 150 000km for the CO2 resulting in its production to be offset. In the case of CFC, the environmental pollution is shifted to the phase of fibre production and its unresolved disposal. This is where the advantages of biocomposites come in. They are also suited to produce lightweight materials. But here we have a material component with a bio-based raw material origin. At the same time, a natural fibre can be burned much more easily, CO2

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ENVIRO ‘Shale gas boom has crushed recycling’ in USA

THE shale gas boom has virtually crushed plastics recycling in the USA, according to a recycling sector expert. In a presentation at the Global Plastics Summit in Houston, Texas, in June, North American recycling market analyst Nina Bellucci Butler, was blunt in her assessment of recycling economics. “The shale gas boom has crushed the economics of plastics recycling,” she said. “That’s been the biggest impact.” The development of large supplies of affordable natural gas and oil from shale deposits throughout the USA has provided resin makers – primarily of polyethylene – with lowpriced feedstock. Resin producers have responded by adding billions of kilograms of new capacity in recent years, keeping prices for virgin material lower than those for recycled resins.

Marriott says it’s done with tiny, plastic toiletry bottles

THE world’s largest hotel chain, Marriott International, is phasing out miniature toiletries in an effort to be more eco-friendly. Marriott International said it would be phasing out miniature bottles of shampoo, conditioner and bath gel in favour of larger, pump-topped bottles at its 7 000 properties worldwide by December 2020. The company estimates the move will keep approximately 700 000kg of plastic – or about 500 million tiny bottles – from ending up in landfills each year. California lawmakers are weighing a bill that would ban hotels from using small, plastic bottles for guests starting in 2023, and the European Union is slated to ban a wide range of single-use plastic items by 2021. Marriott’s pivot away from tiny toiletries feeds into the company’s larger efforts to limit its environmental impact. The company aims to reduce its landfill waste by 45% and responsibly source its top 10 product purchase categories, including guest amenities, by 2025. 52

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Borealis BC918CF is a suitable material for downgauging thermoformed packaging. As a specially modified BNT copolymer, it provides excellent mechanical strength, good moisture barrier, and pleasing optics. In modified atmosphere packaging (MAP), it provides the necessary barrier to give meat a shelf-life of up to 12 days

Borealis, Mondi collaborate for easier, recyclable, PP-based food packaging Viable and more sustainable alternative to non-recyclable packaging for meat and dairy products BOREALIS has generated a breakthrough application based on its proprietary Borstar Nucleation Technology (BNT) that enhances the circularity of plastic food packaging. Using Borealis BC918CF, a special BNT-modified copolymer, Mondi is producing new monomaterial packaging solutions for meat and dairy products. This offers the same excellent performance characteristics as conventional multimaterial packaging, while also increasing yields for mechanical recycling plants. The Borealis collaboration with Mondi has further shown that even better material performance can be achieved by using the heterophasic copolymer BC918CF in tandem with the random copolymer RB707CF. New material solutions must be found to serve as suitable alternatives to conventional multi-material plastic materials designs that combine such polymers as polyamide (PA), or polyethylene terephthalate (PET) with other materials. Finding truly viable substitutes for multimaterial plastics in food packaging – particularly for chilled products such as cheeses, sliced meats and other foodstuffs packaged on trays – is especially challenging due to complex requirements with regard to safety, hygiene, freshness, as well as visual aesthetics. Innovative polypropylene (PP) solutions based on Borealis BC918CF and Borealis RB707CF are viable monomaterial substitutes for multimaterial plastics. In addition to offering a high moisture barrier, their use enables material cost savings thanks to downgauging, as well as efficient processing on film conversion and packaging lines. The combination of both copolymers in production helps achieve even better performance, including both thermal resistance and high transparency, a key combination for efficient packaging. Borealis BC918CF is a suitable material for downgauging thermoformed packaging. As a specially modified BNT copolymer, it provides excellent mechanical strength, good moisture barrier, and pleasing optics. In modified atmosphere packaging (MAP), it provides the necessary barrier to give meat a shelf-life of up to 12 days. Why Borstar Nucleation Technology is good for converters Borealis developed BNT based on its proprietary Borstar technology. The nucleating effect of BNT differs from the standard approach of adding a nucleating agent during pelletisation: the nucleating effect here is obtained in situ, in the polymerisation reactor, during the manufacture of PP. This yields several obvious benefits, including a stronger nucleation effect as well as consistent and better dispersion of the nucleating agent. There is no reaction with other additives, such as colour master batches. It offers low taste and odour, and enables full compliance with food contact regulations. www.borealisgroup.com

www.mondigroup.com

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PEOPLE

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Fresh start for Mark Varrie MARK Varrie has started Plastic Equipment Supplies, this being partly the result of the need, due to various circumstances, to shut down his previous venture, Your Technical Solutions, and start a new chapter. But the process has also created renewal and opportunity for Mark and PES’s small team, specifically in that they now know exactly what to focus on and what to watch out for. Mark qualified as a toolmaker in 1983 and has been working in the industry since, his main roles being the sale, commissioning and servicing of production machinery. He worked for his father’s company, Plasquip, one of the first to popularise machinery from the Far East, from the mid-1970s, then went on his own in 2008. He has developed a reputation for reliability, which was necessary as he has been servicing the plastics industry and commissioning machines continuously. But that’s all behind him now: Plastic Equipment Supplies represents Liguang of China (injection moulding); KaiMei of Taiwan (blow moulding), a range of ancillary equipment including mould temperature controllers from ToolTemp (Switzerland); machine control systems from Techmation; and granulators, chillers from Genox and other accessories from Constant Machinery and Mitex, It also supplies recycling lines and moulds.

Berry Global tie-up creates new dawn for Astrapak SA group assimilates into second global business BERRY Global has introduced a new dawn for Astrapak through which the South African group has become part of an even larger global group. Following Astra’s purchase by and assimilation into the RPC group, also a world player in the plastic packaging sector, in 2017, the Astrapak companies moved into a global category. And now, following RPC’s purchase in turn by Berry Global group of the USA, the SA businesses are truly part of an international entity – and have an even greater opportunity to shine. Berry’s combined global footprint will consist of over 290 locations worldwide, including locations in North and South America, Europe, Asia, Africa and Australia. The pro forma combined business employs over 48,000 people across six continents with sales of approximately $13-billion based on the latest published financial statements of Berry and RPC. “I’m thrilled that our new registered name is Berry Astrapak. The acquisition by Berry of RPC creates a leading global supplier of valued-added protective solutions and one of the world’s largest plastic packaging companies,” said Berry Astrapak CEO Robin Moore. As Berry globalises its business so it creates exciting opportunities

for Astrapak and its customer base. With the association to Berry comes greater opportunity, offering increased access to technology, training and development, and a far wider product range, added Moore. During this exciting time of change, Berry Astrapak has taken the opportunity to introduce changes within their own senior management team. Craig Matthews will now assume the responsibility of MD of Berry Astrapak with the formal handover of full management responsibility from 1 October. Another development is that of the establishment of a new Business Development portfolio, to be managed by Douglas Slogrove as group business development manager, executing our strategic objective to offer our world-class innovation and solutions. Other appointments include those of Dylan Groves, as group sales executive, along with his team of sales and key account managers, and that of Nawaaz Kalick, who formally assumes the role of group operations executive, to deliver more focus to the operational aspect of the company to optimise performance and best practices.

Robin Moore is CEO of the newly named Berry Astrapak group

Douglas Slogrove is group business development manager

PES operates out of Durban but is actively nationally. • Contact Mark on 078 231 7486 www.pesza.co.za Craig Matthews has been appointed MD

Nawaaz Kalick is group operations executive

Dylan Groves, as group sales executive


On the move in 2013 and joined Rare, also a pipe manufacturing business, in Kliprivier south of Joburg, but has now made the trek back. Steve Ashley has joined Pipe-Tech in Cape Town. He was previously at HMT in Wadeville and before that at Gazelle in Krugersdorp. Charles Goldman has joined Shaft Mouldings in Cape Town. David Drew has left Alpa Trading SA and is taking a break. Drew was at Boxmore and, following its integration in the Austrian Alpla group, for 12 years. His most recent position was that of chief commercial officer for the group, based at the Samrand plant in Johannesburg, and he was often Alpla SA’s spokesman at industry events. Drew was in 2017 the unofficial but main industry spokesman for the container manufacturing sector during the drawing up of the Sugar Tax legislation, his ability to explain the complexities created by the legislation for carbonated softdrink manufacturers, particularly to government officials (as well as people within the industry), played an important rôle in ameliorating the initially drastic proposals. Andrea Protti has been appointed as the SA agent for Coster of Italy, a world-leading manufacturer of aerosol valves and actuators, spray caps, spray pumps and dispensers. This in an area in which Andrea has considerable experience: with his former company RAP Products, Andrea was for long one of the leading developers of containers with sprayers and pumps, which require specific design nuance. His decision to sell the business to a corporate group in 2008 ultimately stymied his natural flare

Adidas ‘Run For The Oceans’

OVER 200 runners and walkers in Cape Town chose between a 5km or 8km distance from St James to Muizenberg and back; while close to 50 runners and walkers in Johannesburg completed 5km at Robyn Park for the global adidas movement, Run For The Oceans on World Oceans Day on 8 June. Among the runners were celebrities like Bryan Habana, Damian Willemse, Notshe Sikhumbuzo, Salmaan Moerat and Laura Wolvaardt, The events were held in partnership with Hanli Prinsloo’s foundation, I Am Water, as well as The Beach Co-Op. In Cape Town, the I Am Water team hosted ocean experience workshops for the children. A total of 62kg of litter was collected in Cape Town and 240kg in Johannesburg.

www.adidas.com/parley

for this specialisation and, following his departure, created a knock-on effect that delayed full recovery. Now, however, Andrea is back where he belongs, servicing the container dispensing sector with a full range of solutions. Besides spray packaging solutions, Coster is also a supplier of filling equipment. Morne Greybe has been appointed production manager at Wirquin in Somerset East. Wirquin is a French business and a world-leading manufacturer of sanitary systems and components; it has been operating in the Eastern Cape since 2009. Martin Carew has started Innopack, his own company, which is involved in the supply of barrier flexible and rigid packaging to the food industry. Carew is based in Johannesburg, but Innopack is active nationally; it operates a warehouse in KZN. Innopack has gained the agency for Südpack of Germany, a supplier of a range of advanced films. He is also working with a local convertor to supply printed laminates for my client base. Leigh Pollard has left KAP Industrial Holdings. He was CEO of the KAP Chemicals Division, owner of Safripol Sasolburg and Safripol Durban. James Hynd has left Constantia Afripak and in fact moved out of the industry all together. Stephan Breytenbach has been transferred to Cape Town by Protea Chemicals, from Durban. Mukesh Akoobhai has left Safripol Durban and is taking some time off. Mukesh was plant manager at the Safripol PET plant in Jacobs (formerly called Hosaf).

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Nico van Niekerk has been appointed CEO of the Polymers business at Safripol. Nico graduated from the University of Stellenbosch in 1986 as a chemical engineer. He has also completed an MBA and a Global Executive Development Programme through GIBS. He started his career at the Atomic Energy Corporation and joined Safripol in 1989. During his 30-year career in polymers he has held various positions in engineering, production management and technology management. The Dow Chemical Company, which owned Safripol, appointed Nico to start up and optimize the Dow PP plants in Europe and the USA, where he worked and lived for one and two-and-a-half years respectively. In 2003 Nico returned to South Africa and was part of the MBO of Safripol with majority shareholder Rockwood Capital. KAP acquired Safripol in 2017, at which time Nico was the COO. He was appointed as CEO in July this year. The Polymers business includes the HD and PP manufacturing plant in Sasolburg and the PET plant in Jacobs, Durban. Kenny Watt has joined Pexmart at Rosslyn north of Pretoria, thus returning to the site where he previously worked for Marley, and before that Petzetakis. He has spent the past two years at Marley in Nigel, almost exactly the opposite of Gauteng, to the southwest of Joburg. His return is a result of Pexmart having bought the assets of Marley after it decided to exit the pipe manufacturing sector. Herman Fick has returned to Flo-Tek in Clayville, Olifantsfontein. He left there

Nico van Niekerk has been appointed CEO of Safripol’s Polymers business


PEOPLE ZERMA Machinery & Recycling Technology celebrated its 20th anniversary of manufacturing in Shanghai during September. Zerma remains a German family-owned and family-run business, with the majority of machines destined for export. Europe and North America remain Zerma’s largest markets. The anniversary celebration held in the Zerma factory in Shanghai, saw all 280 employees taking part, many of whom have been with the company since 1999. Pictured at the celebration were the company owners with several of their international partners, including Jeff Cawcutt of Zerma Africa (third from left).

www.zerma.co.za

Zerma celebrates 20th anniversary in Shanghai

Polyflor SA helps refurbish

Ngwelezane Hospital paediatric burns unit

Polyflor’s donation comprised of Pearlazzo PUR sheeting in Mineral, Sunrise, Purple Crush (515m2), Hydro Evolve 2mm in Tigris (40m2), Polysafe Verona 2mm in Horizon Blue (80m2), welding rods, coving and capping strips, wall guards and corner guards. Beautiful waterjet cut-outs of typical African images using the Gradus SureProtect Endure wall protection range, transformed the facility into a highly functional, yet bright, happy space

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Beautiful floors, accessories and waterjet cut-outs help transform rural KZN hospital POLYFLOR SA once again partnered with the Carte Blanche Making a Difference Trust to help refurbish the paediatric facilities and services for trauma and burns patients at Ngwelezana Hospital, by donating flooring and wall protection products and services valued at close to R400 000. According to Tandy Coleman, CEO of Polyflor SA, this project was very dear to her team’s hearts as it cares for and treats KZN’s littlest burn and trauma

victims. Situated approximately 20km from Richards Bay in northern KwaZuluNatal, the Ngwelezana Hospital is a 554-bed facility that provides district, regional and tertiary services to densely populated communities from the King Cetshwayo, Umkhanyakude and Zululand districts. Above and beyond the seed capital of R10.3 million contributed to the Carte Blanche Making a Difference Trust by South32 to initiate this project, Polyflor

SA was one of 30 companies who generously donated material, equipment, services and advice to help realise the dream of creating a brand-new, 22-bed paediatric burns unit. It now also has the best purpose-fit medical equipment, essential clinical dry and wet treatment areas and custom-designed air treatment facilities which are required for the optimal treatment of burns patients. www.polyflor.co.za


Showing our colours – closing material cycles At ENGEL, we embrace responsibility, helping our customers achieve sustainable injection moulding production. At the heart of this are our inject 4.0 solutions for the smart factory, which also open up new opportunities for the Circular Economy. For instance, the iQ weight control software balances out process fluctuations when processing recycled material. Consistent high part quality increases the range of possible uses for the recycled material. Technologically, we are also promoting increased use of recycled material. With the new ENGEL skinmelt process, we are enabling a high proportion of recycled material even in complex component geometries. The bottom line: green is more than the colour of our machines. Come and see what it all looks like at K 2019 (Hall 15, Stand C58).

engel-k-online.com

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DESIGN The winning design showcases South Africa’s diverse heritage and features figures in traditional dress and playing the vuvuzela, set against a brightly coloured background

The winner, Jiyaad Greeff, a Grade 10 pupil at the National School of the Arts (NSA) with world-renowned Ndebele artist, Esther Mahlangu

Winning bread packaging design inspired by Ndebele artist

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Third year Albany celebrates Heritage Day by printing original artwork on its packaging TO celebrate South Africa’s rich history of art and food, Albany Bakeries printed a young South African artist’s winning design on the packaging of millions of loaves of its Albany Superior White and Albany Superior Brown bread during September. The winning design, by Jiyaad Greeff, a Grade 10 pupil at the National School of the Arts (NSA), was chosen from 28 entries for the 2019 Albany Packaging Award. Young artists were briefed to create a design based on the theme ‘New Generation Traditional Design’ inspired by the work of world-renowned Ndebele artist, Esther Mahlangu. As part of its efforts to help preserve South Africa’s culture by inspiring

young artists to celebrate their country’s heritage through creativity, Albany Bakeries partnered with the NSA and Dr Mahlangu to hold a Master Class for NSA students last year. Inspired by Dr Mahlangu and drawing on their own knowledge of their cultural heritage, participating artists were encouraged to find new generation contemporary expression in traditional design, specifically with the use of symmetrical shapes and a range of colours. “All South Africans are born of diversity with a proud claim on their own and other heritage roots,” says Managing Director of Albany Bakeries, Matshela Seshibe. “The brief encouraged artists to explore the wealth that lies in the pool of

traditional inspiration. We were looking for impact, colour, beauty and work that depicts the power of heritage in a contemporary world.” The winning design incorporates inspiration from Mahlangu’s worldfamous, contemporary painting technique and showcases South Africa’s diverse heritage, alongside its promising future. The design features figures in traditional dress and playing the vuvuzela, set against a brightly coloured background. A range of bold, bright colours is used to represent South Africa’s multicultural heritage. This is the third year that Albany has celebrated Heritage Day by printing original artwork on its packaging.


GOLDEN EAGLE PLASTIC MACHINERY

FLOW REGULATORS TOPSTAR ROBOTICS

MACHINE MOUNTS, MOULD CLAMPS, HOPPER MAGNETS

ANCILLARY EQUIPMENT

HIGH QUALITY PRECISION MOULDS

With years of expertise in the Plastic Industry, we can help from start up to large installations. Our specialities are energy saving solutions and advice, assistance with production costing, forecasts and, most importantly, being there for our customers long after we have done our installations. 4 Newton Road, Hughes , Ext. 15 Boksburg P O Box 6250, Dunswart 1508 Tel: +27 11 823 5840/41 • Fax: +27 11 823 4969 Email: mail@pmsplastics.co.za • www.pmsplastics.co.za

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2019/10/03 13:15


INTERNATIONAL DESIGN EXCELLENCE AWARDS WINNERS

Design leveraged

Highlighting design in many forms THE International Design Excellence Awards (IDEA) is one of the longest running and most prestigious design awards programmes in existence. Originally founded to recognise exceptional achievement in industrial design, the programme has grown to highlight design in many forms – including design strategy, branding, digital interaction and so much more. Each year, thousands of entries are submitted by design teams across the globe, making IDEA one of the largest and most widely anticipated annual awards

programmes in the world. Since its inception, the goal of IDEA has always remained to identify and honour the pinnacle of design excellence. Through a close partnership with The Henry Ford Museum, IDEA winners become a part of its permanent collection and remain an ever-present symbol of ingenuity and mastery of craft. Here we take a look at just some of the many winners who used plastics, rubber or composites in their designs.

GOLD AWARDS

Genesis Essentia Concept Essentia is an all-electric high-performance concept car for the luxury automotive brand Genesis. Essentia features a lightweight carbon-fibre monocoque, a multi-motor electric powertrain and a custom-tailored interior. The design of the battery pack sets Essentia apart. By housing it in an I-shaped structure in the centre tunnel, rather than underneath the passenger compartment, Essentia is able to achieve a super-low 127cm roofline and spacious cockpit-style cabin.

Designed by Genesis Design Center

www.genesis.com

www.logitech.com

Logitech MX Vertical MX Vertical is an advanced ergonomic mouse that combines science-driven design with the performance of Logitech’s MX series. Its natural handshake position has been proven to reduce wrist and forearm strain related to repetitive strain injuries, and the unique 57-degree vertical angle has been optimized for an ergonomic posture without compromising a pixel of performance. MX Vertical has a 4000-dpi high-precision sensor resulting in four times less precision errors. It stays powered for up to five months on a full charge and gets three hours of use from a one-minute quick charge.

Designed by Logitech Design Team Europe and Design Partners, Ireland 60 OCT / NOV 2019


to its fullest power GOLD AWARDS

LG Dual Wing Ceiling Fan Ceiling fans usually have a dead zone in the middle that is incapable of generating wind. The LG Dual Wing Ceiling Fan has solved this limitation by placing dual blades at the centre that eliminate the dead angle, enabling the fan to provide more coverage than competing fans. The dual blades are transparent, which reduces the visual footprint of the fan. The polycarbonate outer shell is tough enough to handle everyday tumbles. The seamless unibody design connecting the three main blades reduces wind www.casper.com/glow-light loss and makes cleaning easier since the blades can be cleaned all at once.

Designed by Hosik Jang, Ilseop So, Seungho Baek, Seungdon Lee & Kangeui Cho of LG Electronics

SILVER AWARDS

ZETA

ZETA is a kayaking helmet designed to seamlessly blend beauty, performance and simplicity. This helmet features: an ABS injection moulded shell, multi-impact moulded DCLAN foam liner, HOG 4.0 BOA retention system, interchangeable compression moulded closed-cell foam fitting pads with a silicone strip to reduce helmet slip, soft nylon webbing, stainless steel rivets and burrs, Duraflex fasteners, and adjusters and stops. The LRP™ (light reflection protection) minimizes glare, temple guards are die cast in aluminum for better protection, and advanced materials lend a more comfortable and less bulky fit, similar to a baseball cap.

Designed by KEM STUDIO for Shred Ready

Edge When travelling for business, people usually prefer to bring a small bag that they can easily carry, rarely leaving room for a hairdryer or iron. Edge solves that dilemma. It has three modules: hair dryer, iron and the handle that powers both.

Designed by Park Chanhong, Lee Taekkyung & Cho Yonghun of Konkuk University, Seoul OCT / NOV 2019 61


INTERNATIONAL DESIGN EXCELLENCE AWARDS WINNERS

Zip Top reusable containers Zip Top reusable containers are 100% platinum silicone containers that stand up, stay open and zip shut. They are all food-grade quality and microwave, dishwasher, oven and freezer safe. Zip Top containers perfectly bridge the gap between a structural container with a lid and flexible zippered plastic bags.

SILVER AWARDS Designed by Rebecca Finell of Zip Top

www.ziptop.com

Tetra Dishwasher The Tetra is a compact countertop dishwasher that cleans in minutes using only 3.8 litres of water. With its own water reservoir, no plumbing is required. Instead, water is manually poured into the unit and dirty water is easily removed via a greywater reservoir. It can be placed on a countertop and plugged into a standard electrical outlet. Tetra uses 80% less water and energy than existing dishwashers. Tetra can wash two full place settings, 10 plates or 12 pint glasses within minutes.

Designed by frog Design for Heatworks www.myheatworks.com/pages/tetra-specs

BRONZE AWARDS

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Lalaboom educational beads Lalaboom educational beads stimulate manipulation, perception and creativity in children aged 10 to 36 months. It has five main functions, each one corresponding to a stage of a child’s learning curve. Its Montessori-style approach allows toddlers to discover the next stage at their own pace through experimentation. In Step 1, children explore colours, shapes and textures. Motor skills are practiced in Step 2 by snapping and twisting the beads. Children are encouraged to explore their creativity in Step 3 by combining beads. Step 4 is a preschool construction game. Step 5 enhances fine motor skills with a lacing function.

Designed by Fabien Fontaine www.lalaboom.toys


We make things better

Speak to us.. We know hot runners!

TEL: 011 462 2990

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info@demaplastech.co.za

www.demaplastech.co.za

2019/09/30 10:51


INTERNATIONAL DESIGN EXCELLENCE AWARDS WINNERS

BRONZE AWARDS

Miracle 360° Fruit Infuser Cup 14oz

A fun and healthy twist on the toddler sippy cup, the Fruit Infuser Cup combines a leak-proof top and 360-degree drinkable edge with a natural way to flavour your child’s water. Simply add your child’s favourite fruit, like strawberries, oranges or blueberries, into the fruit basket, twist it into the bottom and then fill the cup with water. The twist-on fruit extractor breaks up the fruit, allowing it to infuse the water and make a fun, flavorful drink. Bye, bye, juice! Hello, healthy water!

Designed by Quinn Biesinger, Thomas Birkert & Dave Ip of Munchkin Inc. www.munchkin.com

UCO Ware

www.ucogear.com/ucoware

UCO Ware is a collection of easy-to-use spork utensils and mess kits specifically designed to work together to address the needs of camping meals and food storage. The nesting design of the utility spork allows you to stack multiple sporks together. The compact switch spork transforms into a dedicated full-sized spoon, fork and knife. It also telescopes together to form an extra-long utensil for tall food pouches. The lid of the mess kit doubles as a plate, and the premium bamboo version includes a cutting board integrated onto the outside surface.

Designed by Treasure Hinds and Greg Janky of Anvil Studios Design Team

Bose noise-masking sleepbuds

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®

The Bose® noise-masking sleepbuds™ help improve sleep by replacing unwanted noise with soothing sounds. These tiny, comfortable earbuds drown out virtually any outside noise, whether it’s the busy street outside or a noisy sleeping partner, so users can easily fall asleep and stay asleep. The sleepbuds are preloaded with soothing sounds that fade from attention while obscuring unwanted disturbances. An alarm can also be set through the Bose Sleep app so users can wake up without disturbing anyone else in the room.

Designed by Astro Studios and Bose Design Team www.bose.com/en_us/


Exceed™ XP

Exceed™

Enable™

Vistamaxx™

Keep food safe and secure Our performance polymers enable high-integrity, cost-effective packaging to protect and preserve food from production to consumption.

Attend our K2019 TechTalk presentations Visit us at Hall 10 / 10.1

© 2019 ExxonMobil. All trademarks used herein are trademarks or registered trademarks of Exxon Mobil Corporation or one of its subsidiaries. X0419-052E49

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exxonmobilchemical.com

2019/09/17 10:02


COMPOSITES

Baakens River gets

Composites route in keeping with MBDA mission to push for innovation WORK is completed on the R8-million pedestrian bridge over the lower Baakens River to capitalise on the precinct’s mushrooming heritage, culture and outdoor activity hub. Mandela Bay Development Agency (MBDA) spokesperson Luvuyo Bangazi said, in a first for South Africa, the 40-metre arch bridge is made mostly of new generation composite materials,

creating a tourism landmark and at the same time stimulating the Bay-based national composites cluster. “As an urban renewal project, the bridge links Port Elizabeth’s inner city to the already bustling Lower Baakens. It serves as a practical connector, allowing people to park their cars in the expansive parking space on the north side of the river and then stroll across

to see the restored St Peter’s church or attend, for example, a trail run, mountain bike or off-road motorbike race, or to enjoy one of the music and good food events,” Bangazi added. Project manager Thandie Mafu said they had chosen to go the composites route in keeping with the MBDA mission to always push for innovation. Taking the opportunity to boost the

October 2019 date set for

Bloodhound High Speed Test

The team’s ultimate objective is to reach 1 609km/h

THE Bloodhound Land Speed Record team report that the Bloodhound land speed record car will run for the first time on its dry lake bed race track at Hakskeen Pan, in the Northern Cape, in October 2019. Following the successful 320km/h UK runway trials at Cornwall Airport Newquay in October 2017, the car is expected to reach speeds in excess of 800km/h, as part of the Bloodhound team’s larger objective of beating the current land speed record (LSR) of 1 228km/h. The team’s ultimate objective is to reach 1 609.34km/h. The front of the car is made from carbon fibre, while the rear is made from aerospace-grade aluminium and other composites to support the engine, and eventually the rocket. It also has metal wheels designed to rotate 170 times a second.

braking system, more air pressure and load sensors, and a fire detection and suppression system. The Bloodhound LSR team’s attempt on the world land speed record is the first in the digital era. Data from hundreds of sensors on the car will be shared in real time to allow budding engineers to see exactly how the car is behaving as it dices with physics. The trials in South Africa will enable the team to test this data distribution, as well as the live video stream, at high speeds in preparation for the land speed record runs.

Preparing for deployment Since the project’s relaunch in March 2019, the team have been focussing on both the logistics of deploying the team and car to the Kalahari Desert and converting the car from its runway design to high speed testing specs. This has included uprating springs and dampers, and adding the parachute 66

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The 40-metre arch bridge is made mostly of new generation composite materials, creating a tourism landmark

composite bridge Bay’s leading role in this sector, based at the Propella Incubator just up the road, had also made sense. “There was a 3% increase in the capital cost over going only with traditional steel and timber, but we will easily recoup this in reduced maintenance,” said Mafu. The bridge is built at an angle to help prevent debris being trapped during heavy rains, and the arch raises the structure

3.37 metres at its mid-point, out of the reach of flooding. Lights are cast into the railings, which curve up overhead. The Baakens River The Baakens River is a 23km urban river, which originates on the outskirts of Port Elizabeth in wet sponges. It meanders through the residential suburbs and culminates at the city centre, flowing into the Algoa Bay Harbour.

programme It will also be a full dress rehearsal for the record-breaking campaign, with the team using the time to develop its operational procedures, perfect its practices for desert working and test radio communications. The car, which is 13.5m long and weighs 5.5 tons, is powered by a Rolls-Royce EJ200 jet engine and will eventually include a Nammo rocket. It will be driven by Royal Air Force pilot Andy Green, who was part of the team that set the current LSR. Green has also been involved with the Bloodhound project since its inception.

The city of Port Elizabeth in fact owes its location to the Baakens River due to the availability of freshwater for Dutch sailors in the late 18th century. Its name was coined by the Dutch East India Company who placed a beacon at the mouth of the river to claim the right to the water source. They termed this source ‘Baakjes Fonteyn’ that ultimately translated to ‘Baakens’.

Aerontec expands RTV silicone range

OCT / NOV 2019 67

CAPE TOWN-based Aerontec has expanded the range of room temperature vulcanizing (RTV) silicones to include a line of addition cure, also known as platinum cure, silicones. The silicone range now comprises Pure Sil 20 Pink and Pure Sil 30 Purple condensation curing silicones. The condensation cure silicones are the economical work horse of the industry. These silicones are insensitive to cure inhibition and are used for a wide range of industrial applications, movie special effects and moulds for casting polyester, epoxy, polyurethane, masonry, gypsum and candle wax. Cape Town based Aerontec is also testing the new Pro Sil 25 Green, which is a highly thixotropic, very fast curing silicone designed for brush on reusable vacuum bags. The addition cure silicones are food safe and can be used for making food moulds. Addition cure silicones can be trickier to use as they are sensitive to cure inhibition, in which they remain uncured, or the surface in contact with the mould remains uncured. Cure inhibition can be caused by a huge list of chemicals, but typically condensation cure silicones, latex (such as latex gloves), sulphur based clays and fresh amines (epoxy) are the usual culprits. www.aerontec.co.za

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COMPOSITES

Beautiful and functional – the role of biomimicry in additive manufacturing Innovation inspired by nature By Prof Anton du Plessis, University of Stellenbosch

ADDITIVE manufacturing technology, also known as 3D printing, has shown tremendous growth and development over the last few years. Today it is possible to print not only plastic prototypes, but serious functional end-use mechanical parts can be produced in a variety of material types including a large range of polymers, composites, ceramics and metals. While it is an expensive process, the main advantage is the complexity of design that can be realised by this method. This is where biomimicry comes in. Biomimicry is “innovation inspired by

nature,” or “the conscious emulation of nature’s genius”, as described by Benuys in 1997. Nature has been optimising complex, beautiful and functional structures over more than 3.8 billion years, so it makes sense for us to learn from these structures and use the principles for engineering design. A team of researchers led by Prof Anton du Plessis from the Department of Physics at Stellenbosch University, compiled a comprehensive review of the topic of biomimetic design for additive manufacturing, focusing on functional end-use parts. The paper, titled “Beautiful and Functional: A Review of Biomimetic Design in Additive

Manufacturing” was published in the journal Additive Manufacturing recently. The authors present a summary and categorisation of the different forms of biomimicry currently in use in this field, highlighting the advantages of each approach by using examples from the recent literature. Most of the examples are focused on metal parts produced using the technique of laser powder bed fusion, a special form of additive manufacturing allowing especially high-detail and complex designs. However, the principles and especially the categorisation of biomimetic approaches are applicable to all forms of 3D printing. For example, the graphical

There’s a new carbon fibre filament in town Additive manufacturing is one step closer to industrial production ROYAL DSM, a global science-based company in Nutrition, Health and Sustainable Living has recently launched a new carbon fibre filled grade PA6/66 filament Novamid ID1030 CF10 for 3D printing. Despite the low carbon fibre loading of 10% – much lower than other carbon filled materials – it produces functional prototyping and industrial parts with properties close to what is usually achievable only by injection moulding while matching the easy and fast printing of unreinforced plastics. Novamid ID1030 CF10 3D is designed for printing structural parts which are clearly stronger, stiffer and tougher with higher tensile strength and modulus, high dimensional stability and free of warpage. These excellent mechanical properties and smooth appearance make it ideal for a very broad range of applications that require robust performance, possibly 68

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at elevated temperatures such as automotive under-the-hood, protective and supporting sports gear; manufacturing jigs and fixtures; medical braces and prosthetics. It’s also a go-to-material for light weight applications across various vertical markets. The material can be printed on standard desktop fused filament fabrication (FFF) machines with a hardened nozzle. Tests have shown that users can run their printers at the same speeds as with unreinforced plastics, while achieving considerably better strength and toughness.

Novamid ID1030 CF10 is designed for printing functional prototypes and industrial applications

www.dsm.com

2019/10/06 12:48


Figure 1: An example of a biomimetic titanium bracket – the obvious advantage here is light-weighting of the structure compared to a traditionally designed component. The result is both beautiful and functional. Image: Anton du Plessis References [1] J. Benyus, Biomimicry: Innovation inspired by nature, (1997). http://www.academia.edu/ download/5239337/biomimicry-innovationinspired-by-nature.pdf (accessed September 2, 2018). [2] A. du Plessis, C. Broeckhoven, I. Yadroitsava, I. Yadroitsev, C.H. Hands, R. Kunju, D. Bhate, Beautiful and Functional: A Review of Biomimetic Design in Additive Manufacturing, Addit. Manuf. (2019). doi:10.1016/J.ADDMA.2019.03.033.

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evolutionary processes in nature, where in each iteration an improved structure is revealed. Finally, the lattice design is itself similar to cellular structures in nature, such as cork or wood cells, but optimised here for providing not only lightweight but also good stiffness of the structure. • For more information on this work you can access the paper here: https://doi. org/10.1016/j.addma.2019.03.033 • Or contact the lead author, Prof Anton du Plessis at email: anton2@sun.ac.za • Research group: http://blogs.sun.ac.za/ duplessis/

OCT / NOV 2019

abstract of the paper demonstrates an example of a metal part (titanium alloy) designed using a combination of two biomimetic design approaches: simulation-driven design and latticing (cellular design). The simulation-driven design process starts with structural mechanical simulations in an initial design space, to identify the areas of highest and lowest stress, and removes material in low-stress areas. This is followed by another iteration of simulation and the removal and addition of material. This iterative process is similar to

2019/10/06 2019/09/12 12:49 12:01


MIDDLE EAST

Drone attacks prove how escalation in tensions in Middle East can impact global economy beyond price of oil Most Saudi polymer plants had their feedstock cut by 30-50% for much of September

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OCT / NOV 2019

BY NIALL MARSHALL

EVEN by the standards of the Middle East, the last month has been ‘interesting’. Drone and cruise missile attacks on Saudi Arabian oil processing facilities had a brief but significant impact on the petrochemical industry. The attack on these upstream oil facilities effectively reduced Saudi Arabia’s crude oil supply and resulted in a 20% spike in global oil prices. Additionally, most Saudi polymer plants had their feedstock cut by 3050% for much of September, resulting in lower production rates and several plant shutdowns. Although these disruptions are unlikely to have any lasting impact on the global polymer market, they do illustrate how any escalation in tensions in the Middle East can impact the global economy beyond just the price of oil. On 14 September, Saudi Arabia’s second largest oilfield at Khurais, and the largest oil processing plant in the world at Abqaiq, were hit by targeted cruise missiles and drones, disabling both facilities. Responsibility was claimed by the Yemeni Houthi militia that overthrew the government of Abdrabbuh Munsur Hadi in 2015. The Houthis, who have launched ballistic missiles at Riyadh and have targeted oil pipelines and even attacked the civilian Abha airport in southern Saudi Arabia,

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receive weapons from Iran and so, unsurprisingly, the drones and missiles used in the attack appear to be Iranian. Both Saudi Arabia and the USA claim that the attack was not carried out by the Houthis from Yemen but that Iran itself launched the attack. Iran, obviously, denies direct involvement and the world waits to see whether the countries who had ‘decisive evidence’ that Saddam Hussein had weapons of mass destruction and that Jamal Khashoggi left the Saudi Embassy in Istanbul alive, are able to convincingly prove that Iran carried out these attacks. Saudi Arabia produces around 5 million tons of polypropylene per year and 9 million tons of polyethylene – that is almost 8% of the global polyethylene capacity. Most of this polymer is exported. It’s not just polymer produced in Saudi Arabia that was affected by the attacks – Saudi Arabia is the largest supplier of MEG (monoethylene glycol) needed for the production of polyester. Any major disruption to Saudi petrochemical production has an impact on global polyolefin availability and prices. The spot prices for PE and PE spiked by almost 5% in China following the attacks although, there is probably enough excess capacity in the market to ensure there are no shortages. In the longer-term it is likely that

the increased capacity due to come on-line in the next couple of years, together with low growth rates due to a global economic slow-down, would partly compensate for any extended loss of Saudi production. But any escalation in the Middle East could also affect the millions of tons of polymer and billions of barrels of oil produced in Kuwait, Qatar and the UAE and exported through the Strait of Hormuz, by impacting supply chains either due to the closing of the Strait of Hormuz to shipping or the unwillingness of shipping lines to risk their ships in a dangerous region (even if there are no wider military or cyber-attacks on the oilpetrochemical infrastructure). Barely a week after the attacks the Energy Minister, Prince Abdulaziz bin Salman bin Abdulaziz, announced that Saudi Arabia would return to ‘full production’ by early October (although full production is still well below its capacity as Saudi Arabia and other OPEC countries produce to reduced targets to stabilize the market). The price of oil has almost returned to the pre-attack levels, polymer availability has not been significantly disrupted and the world has escaped a major disruption. However, there should be no doubt that any escalation will have consequences that extend well beyond the price of oil.

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Günter Maralik +27 83 441 3206 Günter Maralik

Wolfgang Maralik +27 82 771 7271 Wolfgang Maralik

83+27 44166 3206 +27 82 771 7271 Office+27 Cell: 250 1937 • admin@mgmwtrading.co.za Log RoadCell: Unit No. • Roodekop Industrial Area • Germiston Office +27 17 66 250 1937 • admin@mgmwtrading.co.za Log Road Unit No. 17 • our Roodekop Areadetails • Germiston Please note newIndustrial contact

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WORLD NEWS Microplast project – standardised methods to detect microplastics AIMPLAS, the Plastics Technology Centre, is leading the Microplast project, with the participation of Aguas de Valencia and the Universitat de València. This project aims to remove microplastics from both urban and industrial wastewater. It will also develop a standardized methodology to obtain homogeneous data on the presence of these particles in different wastewater sources. The project will respond to growing concern about the existence of plastic particles measuring less than 5mm (known as microplastics) in the environment. The goal of the project is to anticipate legislation on these particles that may be passed in the near future. Its objective is therefore twofold: first, to develop a standardized methodology to quantify the presence of microplastics in wastewater and sludge at urban treatment plants and in industrial water at recycling pilot plants. The second objective is to develop two different technologies for pilot-plant treatment, one using sand and carbon filters, and the other membrane reactors. www.aimplas.net

US-based Milliken to build additives plant in Singapore PLASTICS additives and colorants maker Milliken & Co. plans to build a new plant and technical centre in Singapore. The plant is expected to open in early 2021. Milliken currently operates an applications lab and technical service and sales office in Singapore. The firm has had operations in Singapore for 20 years. The new plant will be able to make several Milliken plastic additives. Primarily, the site will make Hyperform-brand nucleating agents for polypropylene and polyethylene resins. The new facility also will make specialty colourants for a broad range of product applications, including home and laundry care, personal care, industrial and institutional cleaners, and polyurethane foams. 72

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Dow helping to build schools 70% of each plastic brick is made of hard-to-recycle plastic

DOW is working on several initiatives to solve the global plastic waste issue including helping to build schools out of hard-to-recycle plastic waste in Colombia. About 70% of each plastic brick is made of hard-to-recycle plastic, such as flexible films, foam to-go containers, plastic cups, straws and lids. Solving the global plastic waste issue is a hugely daunting task. However, for Dow Chemical, it’s all about working with one community at a time. The company has launched a key initiative that can make sustainable innovation economically viable and beneficial for companies and communities worldwide. In 2016, the Colombian government identified a country-wide deficit of 30 000 schools, which was disproportionately impacting students in poor, rural or isolated areas. At the same time, the country was grappling with how to address the 12 million tons of waste it produces annually, only 17% of which is recycled. Recognising the potential to help address these issues, Dow partnered with Colombian startup Conceptos Plásticos to launch Aulas Verdes (green classrooms), a unique initiative that builds schools in underserved communities using bricks made of plastic waste. “At Dow, we are committed to not only advancing the circular economy by developing new applications for post-consumer plastic waste, but also helping to address important

Edible packaging receives UK government funding A Lucozade Ribena Suntory-backed edible, plastic-free packaging innovation is taking a step closer to being rolled out – thanks to Innovate UK, part of UK Research and Innovation – the UK Government’s innovation agency. The capsules, called Oohos, are made entirely from seaweed extract, a material called Notpla, and offer a way to deliver drinks under 100ml in a plastic-free form. They are not only completely edible but also claim to be naturally biodegrade in four to six weeks. The funding will focus on perfecting the technology behind Oohos, with the aim of creating a machine that could be installed in gyms or restaurants and manufacture up to 3 000 Oohos a day with drinks like Lucozade Sport. The machine could operate similarly to a barista coffee machine and allow customers to buy liquid-filled Oohos directly from locations such as local coffee shops and gyms.

OCT / NOV 2019

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Children and their teacher are very happy with their new class which was built in Gonzagueville, Abidjan, Côte d’Ivoire, with plastic bricks made out of recycled plastic

social challenges,” said Dow’s Daniella Souza Miranda, commercial vice president of plastics (P&SP) in Latin America.

Expanding the initiative Dow plans to continue with Aulas Verdes in Colombia, but are actively exploring opportunities to replicate this initiative in other parts of Latin America. “Aulas Verdes is one of many ways Dow is helping to drive the circular economy by delivering solutions that close the resource loop in key markets,” Souza Miranda says. “For example, our global plastic roads initiatives have diverted about 100 tons of waste from landfills for use in modified asphalt in places like Texas in the US, Indonesia and Thailand. The organisation also has a variety of ongoing initiatives that aim to collect and convert hard-to-recycle plastic waste into valuable resources, such as fuel or fertilizer.

Alpla to reduce its carbon footprint by 10%

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THE ‘Alpla Kids’ – the boys and girls at the company’s crèche in Hard, Austria, are the ‘title heroes’ of Alpla’s third sustainability report. Alpla’s sustainability record for the past three years is positive: energy consumption in relation to production volumes was reduced by 6.6% and consumption of fresh water in relation to material usage by 40%. The company even exceeded its target for using recycled materials. The company was also able to reduce its carbon footprint, albeit not as much as planned. Alpla has 178 plants in 46 countries. Of these plants, 72 are ‘in-house’, meaning they are directly part of the customer’s operations, reducing transport routes and carbon emissions. Alpla can also point to several flagship initiatives in the area of product development: from bottles made entirely of recyclate and the home-compostable coffee capsule to the Simple One, a HDPE bottle that is up to 60% lighter than standard bottles. From 2022, the company wants to bring at least three innovations to the market each year. It also aims to reduce its carbon footprint absolutely by 10% – even with its projected annual growth of 3%.

www.aulasverdes.co

The process The construction model implemented by Aulas Verdes leverages both proprietary technologies from Conceptos Plásticos and an array of Dow products that enhance the durability and energy efficiency of both the construction process and the classrooms themselves. One example is Dow’s CoolRoof technology, which effectively reduces 30% of CO2 emissions and generates 88% and 90% more emissivity and reflectance respectively, providing greater safety and comfort to students. A production line of the construction system recovers four thousand tons of plastic annually, equivalent to the reuse of 770 thousand litres of water, 535 thousand kilowatts of energy and 13 thousand tons of CO2. So far, Aulas Verdes has built three schools in Colombia

using 12 tons of hard-to-recycle plastic waste. These schools currently serve 600 students, with a potential reach of 3 000 from surrounding communities. The plan is to complete 15 schools in total by the end of 2019.

www.dow.com

out of plastic waste

www.alpla.com

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2019/10/06 12:56


WORLD NEWS

Haitian sales fall in China as trade war takes a bite

SLOWING economies around the world and the US-China trade conflict pushed sales for Chinese plastics equipment maker Haitian International Holdings down 15% in the first half of the year, reports Plastics News. The Ningbo-based company, China’s largest maker of injection moulding machines, said in an earnings report that sales dropped 14.8% to just a little more than 5 billion Chinese yuan ($700 million) in the six months ending 30 June, down from almost 5.9 billion yuan ($825 million) in the first half of 2018. Sales within China fell 20%, to just over 3.3 billion yuan ($460 million), while exports only fell by 2%, to 1.5 billion yuan ($210 million). It pointed to slowing demand in the Chinese auto market and lower exports of things like household appliances as hurting investor confidence in manufacturing. “With the increasing uncertainty of external demand due to the trade war, the purchasing managers’ index for China’s manufacturing sector in the first half of the year hovered around 50, indicating the decline in demand in China’s market resulting from the lack of domestic consumption,” Haitian said. The one bright spot was in its Zhafir all-electric machines, where sales rose 13.6% 773 million yuan ($108.1 million). Meanwhile, Hong Kong-based plastics machinery maker Chen Hsong Holdings Ltd said sales were down 2%, to HK$1.63 billion (US$207.7 million) in the six months ending 31 March and did not expect any improvement. “The group believes that the market conditions in China will continue to be lackluster in the near future over uncertainties over the trade war with USA,” Chen Hsong said. “International markets will also feel the dark pressure of USA unilateralism, making any predictions unreliable.” 74

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First lightweight PET bottles for pasteurised beer The PET bottles feature a crown metal cap, replicating the standard glass bottle

Providing up to four months’ shelf life AMCOR has adapted its leading-edge design technology to develop the first polyethylene terephthalate (PET) bottles for pasteurised beer in Brazil. The company designed custom 600ml containers for beverage maker New Age Bebidas, Leme, São Paulo, that feature the beauty of a glass-like, champagne-style base combined with the convenience of lightweight and shatter-resistant PET. Amcor’s design showcases New Age’s Salzburg craft beer brand and differentiates it from standard glass bottle designs. It features a crown metal cap, replicating the standard glass bottle. The PET containers are a replacement for glass during the filling and capping process, withstanding the internal pressure and high-heat conditions of the tunnel pasteurization process. Amcor uses an oxygen scavenger barrier additive to prevent oxygen ingress and egress, providing up to four months of shelf life. The bottle is compatible with existing recycling streams and is 100% recyclable. The lightweight containers also significantly reduce transportation costs, and energy and CO2 emission reductions along the supply chain. “Innovation and differentiation are the name of the game in the craft beer market in Brazil,” said Fabio Violin, president of New Age Bebidas. “The flexibility of PET packaging allows us to develop a unique replacement for glass that will deliver broad consumer appeal throughout Latin America.”

Giant HDPE pipe in British Columbia THE largest pressure pipe ever used in North America will be connected to a new tertiary wastewater treatment plant in the town of Esquimalt on Vancouver Island, British Columbia.The colossal pipe, made of HDPE, has an outer diameter of 2.3m and extends 2km from the shore.

OCT / NOV 2019

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ExxonMobil, SABIC in massive project in Texas

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manufacturing of various consumer products including automotive coolants, packaging, agricultural film and building, construction materials and clothing. Gulf Coast Growth Ventures is a unique opportunity created by the abundance of low-cost US natural gas and is part of ExxonMobil’s Growing the Gulf initiative initiative, which outlined plans to build and expand manufacturing facilities along the US Gulf Coast, creating more than 45 000 high-paying jobs across the region. The project is part of SABIC’s growth strategy to build new petrochemical facilities in key markets, including the Americas, to address industry demand and achieve the company’s 2025 strategy. Ownership interests in the Gulf Coast Growth Ventures project is 50% ExxonMobil and 50% SABIC, with ExxonMobil as site operator.

OCT / NOV 2019

EXXONMOBIL and SABIC are undertaking the construction of a chemical facility and 1,8 million tons p/a ethane cracker in San Patricio County, Texas, in what is reputed to be the world’s largest steam cracker. “Building the world’s largest steam cracker, with stateof-the-art technology, on the doorstep of rapidly growing Permian production gives this project significant scale and feedstock advantages,” said Darren Woods, chairman and chief executive officer of ExxonMobil. “It is one of several key projects that provide the foundation for significantly increasing the company’s earnings potential.” The joint-venture between ExxonMobil and SABIC, called Gulf Coast Growth Ventures, will include the construction of an ethane steam cracker, two polyethylene units and a monoethylene glycol unit. Construction will begin in the third quarter of 2019 and startup is anticipated by 2022. The facility will produce materials used in the

2019/10/06 12:57


WEB www.masterfiber.basf.com With the high-performance fibres of the MasterFiber series, BASF offers an alternative reinforcement solution for strain-hardening cement-based composites

Master Builders Solutions launches new MasterFiber website Lightweight and durable concrete reinforcement portfolio for sustainable construction THE Master Builders Solutions experts have launched their new website www.masterfiber.basf.com presenting the benefits of MasterFiber and the unique customer service offered by a global team of concrete experts. With MasterFiber, customers can save money and have greater flexibility in the production process. The innovative fibres can partially, or completely, replace the conventional steel reinforcement of concrete. This reflects in a strong sustainability contribution as it enables customers to eliminate the use of steel which is costly, heavy, difficult to handle and generates waste. “MasterFiber is an outstanding innovation that is attracting a lot of interest among our customers,” says Olivier Bayard, regional business segment manager Admixture Systems Europe at Master Builders Solutions.

“For this reason, we decided to give this extraordinary product a dedicated web presence detailing all product characteristics such as fibre types, fields of application and our support service.” Numerous references in several European countries have already proven the sustainability advantages of MasterFiber. Currently, the experts of Master Builders Solutions are supporting the renovation of the port of Barcelona with MasterFiber. A total of 60 000m2 of pavement will be optimized with polypropylene fibres to improve the chloride resistance and durability of the area.

Another success story is that of Spanish precast manufacturer, Uniblok. They achieved extraordinary results with their concrete by incorporating MasterFiber, which increased their efficiency by 10%. MasterFiber offers crucial advantages for numerous fields of application. Mixed into the fresh concrete, the fibres form an internal network and add superior tensile properties to the concrete elements. The result is improved crack control and stronger concrete. The broad portfolio ranges from polypropylene up to steel and PVA fibres including micro, meso and macro fibres.

Covestro products in a new light State-of-the-art web presence for Covestro products A KEY component of Covestro’s digitalisation strategy, the new Covestro Solution Centre, is online. In the new Covestro Solution Centre, more than 2 000 Covestro products can be accessed via an intelligent search, which also includes numerous technical product features.

www.solutions.covestro.com Customers can filter by product characteristics or application areas and compare products side by side, as well as application examples. This helps innovation managers, designers, developers and purchasers to find what they are looking for even faster. They obtain new insights and discover inspiring content. The new website www.solutions.covestro.com is strictly focused on the needs of the customers and supports them in all phases – from the initial idea to ordering the product. In the Covestro Solution Centre, customers can see all product features and examples of applications, download data sheets, compare products, make service requests, inquire samples, find the right contact persons and contact Covestro directly.

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K2019 PREVIEW

‘Plastics shape the future’ Themed days with lectures, keynotes and panel discussions THE World’s No 1 trade fair for plastics and rubber, held in Düsseldorf from 16-23 October, will again be the performance barometer and global innovations marketplace for the entire industry presenting over 3,300 exhibitors from more than 60 countries on approximately 178,000m² of net exhibition space. To the tune of 200,000 trade visitors from throughout the world are expected at the metropolis on the River Rhine. As part of its programme of side events, K in Düsseldorf also extends an invitation to debates on current and explosive topics of relevance to plastics, in particular at the special show – ‘Plastics shape the future’ – in Hall 6/C40. The programme of this forum brings together high-level representatives from political, science, business circles and society. Centre stage this year will be the innovative power of materials and the industry in terms of resource-saving

Addex to introduce Phase 2 of intensive cooling technology Revolutionary approach to cooling the bubble ADDEX INC, a leading supplier of high-performance blown film cooling equipment, will launch Phase 2 of its ‘Intensive Cooling’ technology at the K2019. ‘Intensive Cooling’ is Addex’s revolutionary approach to cooling the bubble. Addex’s patented design change from the common aerodynamics of present-day blown film air rings is responsible for dramatic increases in stability and output. Addex continues

to refine the system for even greater gains when combined with the company’s proprietary auto-profile and IBC systems. Addex, which is celebrating its 30th anniversary this year, enjoys strong commercial success with Intensive Cooling, due largely to repeat orders. The system optimizes performance for both high- and low-melt strength processes. The most popular configuration replaces the conventional dual flow’s low-velocity, diffused-flow lower lip with a very high-velocity, upwardlydirected, and focused air stream, which is mounted flat to the die to create an entirely new lock point, about 25mm above the die lip. The technology is sold

78 OCT / NOV 2019

as part of Addex’s industry standard Laminar Flow air ring, and also in concert with Addex’s auto-profile and IBC systems. Phase 1 Intensive Cooling R&D focused on adapting the technology to run a range of materials; both highand low-melt materials. Step by step, Addex has garnered success with what the industry considers ‘hard to run’ materials. Now in Phase 2, Addex is taking a fresh look at the design of other components within the blown film cooling process, with an eye toward optimising total system performance in combination with Intensive Cooling.

• Visit Addex in Hall 17, stand C41

www.addexinc.com


at K2019 in Düsseldorf processes, digitalisation, functionality, renewable energies, circular economy and sustainability. Also featuring on the agenda will be critical issues such as marine plastic waste, the throw-away mentality associated with plastic packaging and the use of finite resources for their production. The backbone of the special show will be themed days with lectures, keynotes and panel discussions, partly in German, partly in English. Experts from science, industry, politics, local authorities and from non-governmental organisations will provide information and discuss economic, social and ecological challenges and approaches to solutions from the Wednesday to the Tuesday of the trade fair.

• For the detailed programme of the Special Show “Plastics shape the future” go to www.plasticsshapethefuture.de

Dow to showcase design for recyclability packaging

www.k-online.de

• Official Distributor in Southern Africa for BASF

on TPU Elastollan® Thermoplastic Polyurethane

DOW will showcase a comprehensive suite of products and capabilities at K2019 that can help brand owners and converters to address recyclability targets with flexible PE packaging. Designed for recyclability, these prototypes represent different food, home and personal care packaging applications, using Dow’s resins, coatings and adhesives on the most common extrusion and packaging machinery. Dow’s offering comprises of concepts for simple multilayered structures without barrier, more complex packaging with customised barrier for food protection, as well as conversion process redesign – including the use of compatibilisers to help enhance the mechanical recyclability of multilayer packaging and a spout insertion technology. PE-based solutions have been developed for pouches and thermoformed packaging.

• Visit Dow in Hall 8a, stand K48 www.dow.com/k2019

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• 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


K2019 PREVIEW

‘Zero Cooling’ -

revolutionary advance in preform cooling technology

Dramatically reduces injection cycle times AT Nissei ASB Machine Co’s 712m2 booth at K2019, live moulding demonstrations of five ASB-Series machines will showcase ASB’s recently introduced ‘Zero Cooling’ moulding process. First announced in 2018, Zero Cooling – ASB’s revolutionary advance in preform cooling technology – perfectly suits the needs of the cosmetics, personal care, pharmaceutical, household and general food packaging industries as it enables increased product quality at significantly shorter moulding cycles than seen previously. Taking full advantage of ASB’s proprietary 4-station, 1-step moulding method, virtually all the required preform cooling is now shifted away from the injection station and into the second, conditioning station to dramatically reduce injection cycle times. Crucially, the Zero Cooling moulding method enables these short cycle times to be achieved while avoiding the need for thin, compromised design preforms that are susceptible to several quality related problems, most notably the undesirable ‘fisheye’, ‘body ring’ and ‘orange peel’. Actual results from typical Zero Cooling moulds have shown 15% or greater increase in stiffness and topload strength, improved control of material distribution and an average of 1.5 times productivity increases while improving on visual quality. Since the container strength has now been improved by better orientation, more scope is available to apply additional light-weighting to the container’s specification.

Perfect visual quality matched with improved physical quality at higher productivity rates – Nissei ASB demonstrate Zero Cooling moulding at K2019

The advanced cooling method also enables the moulding of heavyweight premium cosmetic containers in dramatically shortened cycle times exhibiting no haziness even when using standard, lower cost PET grades, rather than the higher priced specialised, low-crystallisation grades that are normally required.

• Visit Nissei ASB in Hall 14, stand B38

www.nisseiasb.co.jp

Sustainable thinking for plastics Simple and profitable in practice: Krones’ solutions for a closed plastics cycle ONE thing is beyond doubt: how the human race deals with packages and recyclables is going to have to change significantly in the future – away from resource consumption and towards a sustainable closed-cycle economy. While this thinking is only gradually gaining acceptance, Krones is already several steps ahead. Why? Because they keep packaging plastics in a closed circuit. Disposable products like PET bottles thus get a chance for a 80 OCT / NOV 2019

sustainable, eco-compatible life – not just once, but repeatedly. Millions of PET bottles a year are already being recycled on Krones’ MetaPure systems – depending on the demand involved, in different material qualities up to and including food-grade PET. Because the company is pursuing a holistic approach, it is expanding its technology to cover additional types of plastic. Handling preforms with a recyclate

content of up to 100%? With the Contiform stretch blow moulding machines, it’s no problem. The highspeed version from the series, the Contiform 3 Speed, is represented at K2019 by a blow moulding station. With a station output of up to 2,750 containers per hour, it produces application-tailored packages for still water, CSDs and sensitive products. Like all machines in the Contiform series, it has been designed for


Game-changing technologies meet regional collection & sorting STYRENICS Circular Solutions (SCS) will host a panel discussion, ‘True Circularity. Food Contact. Powered by Styrenics’, during the K show this year. The event will start at 2:30pm on Thursday, 17 October and will be followed by a dialogue forum. The venue is Room 8, Congress Centre, Düsseldorf Süd (CCD South), K 2019 trade fair. The discussion will explore the unique capacity of polystyrene for full circularity due to its intrinsic ability to be easily recycled back to its original monomer. Recyclates meet the highest quality demands and are suitable even for food contact. SCS will also analyse where the industry is on the path to implementing and scaling up its game-changing recycling technologies, as well as the opportunities in linking regional postconsumer feedstocks and challenges to be overcome. The dialogue forum that will follow the panel discussion will be an opportunity for

Simple and profitable in practice: Krones’ solutions for a closed plastics cycle

high energy- and media-efficiency. It undercuts the already-very-low energyand compressed-air consumption of the Contiform 3 Pro by another up to 15%.

• Visit Krones in OA Hall 15, stand 15.1

www.krones.com

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guests to circulate and hear directly from major players from all along the value chain. Speakers include:

• Jens Kathmann, Secretary-General,

Styrenics Circular Solutions, a role he took on in October 2018. Previously, he served as Vice President Standard Products EMEA for INEOS Styrolution with over 30 years of experience in the chemical industry, including BASF, in several managerial assignments in Asia and Europe. • Jocelyn Doucet, CEO, Pyrowave, holds a Ph.D. in Chemical Engineering from Polytechnique Montreal, where he has been an adjunct professor since 2011. After a successful career as entrepreneur in the consulting industry, he founded Pyrowave in 2014. The company developed a world-class modular microwaves technology platform for depolymerisation of styrenics and is currently expanding its

application to polyolefins.

• Dr Rüdiger Baunemann, Director

General PlasticsEurope Germany and Regional Director Central Europe at PlasticsEurope. Previously he held several positions at PlasticsEurope Germany around Plastics and Environment, Plastics and Technical Affairs and Plastics and Consumer. • An Vossen, Managing Director, Plarebel • Jürgen Priesters, SVP Circular Economy, Tomra, having taken that position in January 2019 after having led his team as Business Development Director at Tomra Recycling. With over 30 years of solid experience in the recycling industry, he is considered an industry expert in recycling process knowledge, working with key players in the plastics value chain to optimise product design and processes to ensure highest recyclability. www.styrenics-circular-solutions.com


K2019 PREVIEW

A closed loop for big bags made from PP Starlinger ‘circular packaging’

The Starlinger recycling line recoSTAR PET iV+

Circular packaging: a Starlinger rPP big bag

AT K2019, Starlinger will present a closed loop system for big bags made from woven polypropylene. Worldwide, more than 380 million 4-loop big bags (called FIBCs in specialist vocabulary – Flexible Intermediate Bulk Containers) are sold every year; this equals an annual recycling potential of approximately 800 000 tons of material. To turn big bags into big bags once more, the Austrian Starlinger & Co GmbH has developed the concept of ‘circular packaging’ for big bags made from PP fabric. The elaborate concept for a closed loop for big bags that begins with polypropylene granulate and leads back to polypropylene regranulate (rPP) through the process steps of production, usage, recovery and

recycling. A closed loop has the advantage that production occurs within a quality assurance system, and the materials used are documented in a so-called ‘material passport’. In cooperation with renowned big bag manufacturers Louis Blockx and LC Packaging, Starlinger has simulated this loop and produced new big bags from fabric with high rPP content. Samples will be available at K2019, proving that Starlinger rPP big bags show the same quality as big bags made from virgin material in terms of tensile strength, weight, and safety factor.

• Visit Starlinger in Hall 9, stand D22 www.starlinger.com

GN to launch new form/cut/stack thermoformer Ideal for food, medical, and industrial packaging markets GN THERMOFORMING Equipment, a leading manufacturer of servo-driven, roll-fed thermoforming machines for the production of plastic packaging, will launch its new GN580 Thermoformer at K2019. The new form/cut/stack thermoformer is ideal for food, medical, and industrial packaging markets. The GN580 Thermoformer is a smaller version of the company’s highly regarded GN800 launched at K2016. At K2019, the GN580 will run 100% postconsumer recycled (PCR) PET with a common-edge tool, producing meat trays with minimal scrap. Over the years, GN has perfected the commonedge-cut tooling technology for their line of thermoformers. Common-edge tooling offers the ability to form a series of square or rectangular trays in a row or multiple rows while eliminating the 82 OCT / NOV 2019

web between the products. The high-production GN580 thermoformer, with integrated steel rule cutting press and stacking station, is used for the cost-effective manufacturing of packaging products made from all thermoformable materials. The most distinctive features of the GN580 are the high degree of automation as well as the ease of tool change. The GN580 has a forming area of 580mm x 465mm and a cycle time of 45 cycles/min at full stroke. The machine forms

120mm deep parts above and below the sheet line. It also features an operator-friendly HMI with integrated diagnostics and remote connection, an energy recovery system incorporated in all drives, and maintenance-free precision roller bearings in the toggles.

• Visit GN Thermoforming Equipment in Hall 3, stand A36 www.gncanada.com


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2019/09/30 10:53


K2019 PREVIEW

Intelligent machines with adaptive algorithms Wittmann Battenfeld at the K show for the first time

84 OCT / NOV 2019

AT K2019, Wittmann Battenfeld, will exhibit its products and applications under the motto ‘Enjoy Innovation’ for the first time where it will present its innovative injection moulding technologies, processes and applications. The main theme of Wittmann Battenfeld’s presentation at K2019 is to showcase intelligent machines with adaptive algorithms, which

At K2019, Wittmann Battenfeld will demonstrate its expertise by producing a valve for medical technology from an LSR formulation on a machine of its all-electric EcoPower series, an EcoPower 160/350, with a 16-cavity mould

adjust themselves to the ambient conditions. This will be demonstrated with an all-electric EcoPower 55/350, equipped with software packages HiQ-Flow, HiQ-Melt and HiQ-Metering. A W918 robot from Wittmann and all auxiliary appliances connected with the machine, as well as the TEMI+ MES system, are integrated in the machine’s UNILOG B8 control system via Wittmann 4.0. The electronic mould data sheet will also be used on UNILOG B8. The production cell linked together via the Wittmann 4.0 router is thus able to check whether the connected auxiliaries are sufficient for the selected product data set, or if additional equipment is needed. At the Wittmann Battenfeld booth, this production cell will be used on the EcoPower 55/350 to

Recycling economy with a product from the packaging industry –Wittmann Battenfeld will manufacture cosmetic jars with lids from a material completely based on natural ingredients on an EcoPower 240/1100H/130L Combimould using a 4+4-cavity mould. This material can be recycled without any loss of its functional properties

The medical blood tubes manufactured on an EcoPower Xpress 160, and the mould used

produce polycarbonate clothes pegs with a 4-cavity mould. Using this fully integrated production cell, the advantages of integration via Wittmann 4.0 and the TEMI+ MES system will be clearly seen. The product HiQ-Flow will automatically compensate the effect of material viscosity fluctuations, thus ensuring stable parts’ quality and eliminating scrap. To avoid plastic waste, pieces of sprue and bad parts deliberately produced for demonstration purposes will be re-granulated in the new G-Max 9 granulator from Wittmann, and then directly returned to the machine hopper via the vacuum conveying device connected with the granulator.

• Ipex represents Wittmann Battenfeld in SA, www.ipex.co.za • Visit Wittmann Battenfeld in Hall 15, stand C06


Relloy ad '014 05 (Welding) Propak.indd 1 Relloy ad '014 05 (Welding) Propak.indd 1

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K2019 PREVIEW

Winning the challenge!

86 OCT / NOV 2019

Maximum energy efficiency even on small productions MORETTO SpA, leading supplier of automation and auxiliary equipment for the plastic industry, will presents itself as a ‘partner of solutions’ at this year’s K show, capable of listening to customer needs and responding effectively with dedicated and customized products. Starting from the customer and his specific needs, Moretto will provide K2019 visitors with an overview of unique solutions and systems, consisting of energy-saving technologies and 4.0 control and management devices, essential tools for an efficient and sustainable production. A necessary approach to ‘win the challenge’ in a market composed of customers with complex and diversified performance needs based on the sector of application and the production process. Moretto will exhibit the most innovative systems and products for injection moulding, blow moulding and extrusion.

There are two exhibition areas in Hall 11, one specifically dedicated to the extrusion sector, with Contrex brand products, the group brand specialised in the supply of automation and control systems for blown film extrusion (Moretto Hall 11 Stand H 57, Contrex Hall 11 Stand E65). Moretto will also present the X COMB series of dehumidifiers, extended in the range to cover higher production needs. These mini dryers are a real combination of patented Moretto technologies: fully electric (they do not use compressed air), they are equipped with powerful turbocompressors, zeolite technology, the Dew Point equalizer and the exclusive OTX hopper. Also on show will be Moretto’s offerings for energy-saving systems dedicated to packaging and PET. Particular attention will be paid to drying PET granules, a delicate phase especially for large productions, typical

of the rigid packaging and beverage sectors. In a dedicated area of the stand, Moretto will demonstrate a drying system consisting of a XD 800X series dryer combined with the OTX hopper and Moisture Meter Manager. Another Moretto’s unique solution in the market for the drying of technical polymers. The innovative turbocompressors system of the XD 800X series dryer, together with the OTX hoppers, offer extraordinary levels of energy efficiency. Furthermore, the XD 800X dryers do not use either cooling water or compressed air, being this another advantage in the treatment of PET and ensuring energy saving compared to conventional dryers.

• Visit Moretto in Hall 11, stand H57 www.moretto.com

A never before showcase by Rajoo Engineers RAJOO Engineers will demonstrate live, for the first time, two machines: a 7-layer blown film line and a twin screw sheet extrusion line for PET. The 7-layer machine is versatile and can produce barrier film and also work as a POD line; for both symmetrical and asymmetrical structures, with a capacity of 450kg/hr of film. The line is fully loaded with world-class automation – multicomponent batch blending, gsm control, non-contact capacitive sensor for barrier and POD films, automatic profile control and integrated touch screen based supervisory control. And the applications are numerous: packaging (UHT milk, meat, edible

oil), barrier films (vacuum bag, thermoformable, lidding,), and non-barrier films (lamination grade, milk and water packaging, shrink) and more. Rajoo will also demonstrate Lamina rPET – watch bottle flakes being efficiently converted into transparent sheets reaching the 450 kg/hr mark, and that at an energy consumption of just 0.25 unit/kg. “I can proudly say that our products are best-in-class and meet requirements globally,” says Khushboo Chandrakant Doshi, Executive Director, Rajoo Engineers Limited.

• Visit Rajoo Engineers in Hall 16, stand D22

www.rajoo.com


‘Ultra’ vacuum resin dryer has drastically lower energy consumption Uses less than a tenth of the energy needed by a new desiccant dryer THE world’s only vacuum resin dryer designed for plastics processors has a new brand name that reflects its proven capability to pay for itself through substantial savings in energy costs. Now called Ultra®, the dryer uses energy to dry resin at such a drastically lower rate than a comparable new desiccant dryer that its manufacturer, Maguire Products says “with costs so low, it’s almost free”. Ultra low energy dryers are based on technology introduced by Maguire in 2013 under the name VBD™, noted Frank Kavanagh, vice president of marketing and sales. “While the energy needed to heat polymer to its required temperature is roughly the same for both vacuum and desiccant dryers, we now know that the Ultra low energy dryer uses much less energy in the next stage, when the heated resin is actually dried.” Kavanagh cites a typical material drying

example for a process running at 100kg per hour, for 6000 operation hours per year. An average desiccant dryer might run at 60 watts per 0,45kg of material, versus the Ultra Low Energy Dryer that would run at 19 watts per 0,45kg. Each system uses the same amount of energy to bring the material up to temperature from ambient temperature – around 15 watts. This is the energy used to heat. However, the energy used to dry is dramatically different: the desiccant dryer would use a further 45 watts to dry the material so it can be processed, whereas to the same level the Ultra would only use 4 watts – a 10 times difference in energy usage. Ultra low energy dryers are available for throughputs of 68, 136, 272, and 454kg/hr.

• Visit Maguire in Hall 10, stand A26

www.maguire.com

Meraxis: Global plastics distributor to enter stage PLASTICS distributor Meraxis, which evolved from a merger earlier this year, will present its comprehensive portfolio to the industry for the first time at the K show - from strategic procurement of polymers and recyclates to global delivery and digital services. In addition, the company will host panel discussions and interviews at Stand E 27 in Hall 6, which will be broadcasted live at’“Meraxis-Messe TV’: Industry experts will discuss challenges, opportunities and trends in the polymer industry. From Brexit to the latest developments in the key international plastics markets and the opportunities offered by digitalization; industry experts and partners will discuss future trends and developments together with Meraxis representatives. Two talk rounds will be held daily. “We want to show the industry who we

are, what we are able to do and, above all, where we want to go,” says Meraxis CEO, Dr Stefan Girschik. “Our aim at Meraxis is to progressively drive innovation, leverage the opportunities offered by digitalisation and position ourselves accordingly with new business models. To this end, it is important to have an ear at the pulse of time and remain close to our partners in the industry.” Beyond the traditional core business of procurement and distribution, Meraxis forms networks with its partners and works with them on promising solutions: In addition to international trading of plastics and plasticised products of all kinds, the Swiss polymer distributor also develops specific solutions, for example, to increase the efficiency of its customers’ procurement and production processes. As such, Meraxis has developed the digital prototype of a “Meraxis Customer OCT / NOV 2019 87

Portal” together with development partners of the RWTH Aachen University Campus, which will be presented at K2019.

• Visit the Meraxis Group in Hall 6, stand E 27 www.meraxis-group.com/en/


DIARY

Composites boom at PE show ONE of the workshop topics at this year’s African Advanced Manufacturing and Composites Show in Port Elizabeth, is ‘Composites and Material technology - Future Boom’. The workshop takes place on 28 November as part of the African Advanced Manufacturing & Composites Show at the Nelson Mandela Bay Stadium from 27-28 November. Speakers participating at the workshop include Prof Oliver Damm (Fraunhofer senior advisor, South Africa), Yohann Cailleau (JEC World, international sales manager), Bernard Reeksting (Centre for Polymer Technology – director, retired) and Malte Scherner (AAT Composites, director). Special guest speaker, Mark Chapman, the Bloodhound Engineering director, will be speaking about lightweighting and other engineering for the fastest car ever created at the power breakfast on Thursday 28 November. www.africanadvancedmanufacturingshow.co.za

Proving that composites will play a critical role in future innovation, extremely compact, deployable, lightweight composite booms are being developed now for future deep space small spacecraft missions. This is a rendering of a future CubeSat-based solar sailcraft that will use the composite booms under development to deploy, tension and support the reflective ultra-thin membrane. As depicted, such a solar sail can be used to travel to Near Earth Asteroids (NEA) to gather strategic knowledge-gap information for future mission planning. (CREDITS: NASA)

Asia Rubber & Plastics Expo 2020 HOSTED in Shenzhen City, an international economic and trade centre in China, the Asia Rubber & Plastics Expo 2020 from 19-21 March 2020 will put hundreds of quality exhibitors face to face with global professionals on a 30 000m2 show floor at the Shenzhen Convention & Exhibition Centre. Focusing on rubber and plastic products, the show aims at building an international and professional platform for global trade and branding, especially for introducing China’s premium rubber and plastics brands to the world, as well as overseas brands to China. China is an important rubber and 88 OCT / NOV 2019

plastic products consumer, producer, importer and exporter. Data from China Customs suggests that in 2018, China imported 7.5748 million and and exported 0.523 million tons of rubber products. The import and export volumes for plastic products was 0.475 million and 13.119 million tons, respectively. The exhibition will cover rubber and plastic products, materials and machinery, auxiliary equipment, moulds & dies, industrial dyes & additives and printing & packaging. Supported by 100+ global professional media and trade associations, the show had attracted

dozens of exhibitors by the August of 2019. What’s more, its diverse and pertinent live activities and events are also available to all attendees. These include: 2020 Asia Product Design Festival, 2020 Asia Print & Pack Expo, 2020 Asia Industrial Rubber & Plastics Forum, 2020 Asia Rubber & Plastics Products Innovation Competition, 2020 Asia Rubber & Plastics Brands Innovation Forum, 2020 Top 100 Rubber & Plastics Products Enterprises Awards Ceremony and the Welcome Dinner.

• For more info, contact Rita at e-mail: marketing1@grandeurhk.com

www.asiaplasexpo.com/index.php?lang=en


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DIARY

Global plastics industry growing 4-5% annually

COMING UP

THE global plastics and rubber industry has averaged annual growth of between 4 and 5% since the turn of the millennium, with the Middle East witnessing phenomenal expansion in its polymerisation capacities along with the Asia-Pacific region. Figures released by PlasticsEurope showed that the Middle East, together with Africa, accounted for 7.1% of total global plastics production. The statistics were revealed by Messe Düsseldorf GmbH to promote K2019, the largest plastic exhibition in the world, to be held from 16-23 October in Düsseldorf, Germany. In the United Arab Emirates, the local plastics, petrochemicals and rubber industry is forecast to expand an average of 5-6% annually over the next decade. www.k-online.com

Africa Wire, Cable & Tube Conference The inaugural Africa Wire, Cable & Tube Conference, co-organised by CRU and The Southern AfricanGerman Chamber of Commerce and Industry (AHK), taking place from 11-13 November, at Emperors Palace Johannesburg, wire and Tube Düsseldorf, the world’s largest trade shows in this field, are lead sponsors of this important new conference. This unique partnership is the basis for creating an event in which the international wire, cable, tube and pipe supply chain will meet and make new trade partnerships with key African stakeholders. www.germanchamber.co.za

Conductive Plastics Europe 2019 THE 4th European edition of AMI’s Conductive Plastics conference will take place at the Austria Trend Hotel Savoyen in Vienna, Austria, from 5-6 November. Over the past four years, this market-leading event has established itself as the place to learn about current and emerging additive technologies available to developers of electrically and thermally conductive polymeric materials for use in emerging application areas such as electric vehicles, smart devices and LED lighting. The two-day programme covers carbon and graphite additives, including graphenes and other nano-carbon products, as well as novel mineralbased materials. It will discuss formulation and production of conductive materials, as well as the issues that must be addressed at the product design and processing stages of projects. www.ami.international 90 OCT / NOV 2019

Sicomin’s breakthrough MaxCore technology Uses carbon fabrics for laminate and carbon fibres for the thru-foam structure SICOMIN, formulator and supplier of advanced epoxy systems and high-performance composite solutions, showcased a newly developed carbon fibre version of its revolutionary MaxCore technology at Composites Europe in Stuttgart, Germany in September. Sicomin’s MaxCore sandwich core infusion technology was launched at JEC World 2019 earlier this year with both flat and curved panels using glass and flax reinforcement fibres. The ultimate in high-performance, MaxCore technology uses carbon fabrics for the laminate as well as carbon fibres for the thru-foam structure. The 60mm thick demonstration part features 4mm diameter carbon filament bundles inserted through a Rohacell core, with carbon skins infused with Sicomin’s high modulus epoxy system SR 1710, which is optimised for carbon fibre parts. The MaxCore carbon fibre technology is perfect for applications that become too heavy when engineered in glass fibre and require a lightweight and high stiffness solution. MaxCore is an innovative method of dry fibre insertion into thick foam cores, with dry filaments of glass, natural fibres or carbon, for infusion manufacturing of large sandwich structures. Dry fibres are inserted into the foam in multiple orientations and are responsible for 100% of the mechanical properties of the infused processed core. Sicomin is able to place these reinforcement fibres with precise fibre angles and positions within the core and can produce MaxCore panels with core thicknesses as high as 300mm. Due to the mechanical contribution of the fibre reinforcement, MaxCore doesn’t rely on denser and more expensive core material, so it is a cost-effective option compared with classic foam cores used in composite panels. As the core material is solely a carrier for the fibre reinforcement, cores can be selected based on other required parameters such as: fire and smoke behaviour, water resistance, thermoformable ability, low resin absorption or sustainable chemistry.

Sicomin is represented in SA by Aerontec www.aerontec.co.za MaxCore is an innovative method of dry fibre insertion into thick foam cores, with dry filaments of glass, natural fibres or carbon, for infusion manufacturing of large sandwich structures


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DIARY

Global polymer scientists and leaders expected at PPS event in Pretoria

92 OCT / NOV 2019

‘Collaboration is key for technological advancement’ to foster scientific understanding and technical innovation in polymer processing by providing a discussion forum for the worldwide community of engineers and scientists in the field. The thematic range of the PPS encompasses all formulation, conversion and shaping operations applied to polymeric systems in the transformation from their monomeric forms to commercial products. The scientific progamme will include lectures by distinguished plenary and invited speakers from all over the World, contributed oral presentations by both senior and younger scientists and

EFIBCA Open Meeting 15 October, Amsterdam, Holland www.efibca.com

Multilayer Flexible Packaging 2019 18-20 November, Vienna, Austria www.ami.international

AMI’s Polymers for 3D Printing Conf 11-12 December, Dusseldorf, Germany www.ami.international

K2019 16-23 October, Düsseldorf, Germany www.k-online.com

PPS Europe-Africa 18-21 November CSIR Convention Centre, Pretoria www.pps2019.com

2020

Sanitation for Africa 23 October, Johannesburg www.sanitationforafrica.co.za IPSA Gold Pack Awards 30 October, Inanda Club, Sandton www.goldpack.org.za

EVENTS

engineers as well as oral and poster presentations by young post-doctoral fellows, PhD and master students and engineers working in academia and industry. “There will be an effort for the substantial participation of industry since it is our strong belief that the close collaboration between universities, research institutes and centres and industry is the key for technological advancement,” said conference chairperson Suprakas Sinha Ray.

THE International Polymer Processing Society (PPS) is to hold its annual event, PPS2019 (the PPS EuropeAfrica 2019 Regional Conference) at the CSIR International Convention Centre in Pretoria from 18-21 November. The theme of the event is ‘Advanced Plastics as an enabling technology for the Fourth Industrial Revolution’. The PPS Meeting is a leading conference on polymer processing and attracts internationally renowned scientists, engineers and designers in the field of polymer research and development. The goals of the Society as embodied in its constitution are

Conductive Plastics 2019 5-6 November, Vienna, Austria www.ami.international SAPRO Recycled Product of Year 6 November, Johannesburg www.plasticrecyclingsa.co.za OzPipe XIX 7-8 November, Sydney, Australia www.pipa.com.au Africa Wire, Cable & Tube Conference 11-13 November Emperors Palace, Kempton Park www.crugroup.com/events Profiles 2019 12-13 November Marriott Hotel, Cologne, Germany www.ami.international Polyolefin Additives 12-14 November, Vienna, Austria www.ami.international

Polymers in Footwear Conference 19-20 November Sofitel Hotel Kurfürstendamm, Berlin www.ami.international Polymer Foam 2019 26-27 November Marriott Hotel, Hamburg, Germany www.ami,international Think Composites (training course) 26-29 November Johannesburg & Port Elizabeth www.mandelabaycompositescluster.co.za African Adv Manf & Comp 27-28 November Nelson Mandela Bay Stadium, PE www.mandelabaycompositescluster.co.za Thin Wall Packaging 2019 2-4 December, Düsseldorf, Germany www.ami.international Fire Resistance in Plastics 2019 3-5 December Maritim Hotel, Cologne, Germany www.ami.international pacprocess Middle East Africa 2019 9-11 December, Egypt www.pacprocess-mea.com

www.pps2019.com

Africa Energy Indaba 3-4 March, CTICC, Cape Town www.africaenergyindaba.com Complast South Africa 3-5 March, Gallagher Estate, JHB www.smartexpos.in Plastics Regulations 11-12 March, Cologne, Germany www.ami.international/events Machine Tools Africa 2020 12-15 May, Expo Centre, Nasrec, JHB www.machinetoolsafrica.co.za Plastics Recycling World Expo 3-4 June, Messe Essen, Germany www.ami.international Electra Mining Africa 2020 7-11 September, Expo Centre, Nasrec, JHB www.electramining.co.za OzPipe XIX 21-23 September Hotel Okura, Amsterdam, Holland www.pipa.com.au MPC 2020 18-22 October, Cape Town www.impc2020.com Propak Cape 2020 20-22 October, CTICC, Cape Town www.propakcape.co.za


COM I UP NG

AMI’s Profiles returns to Europe for the second edition

Flotech Piping’s Shale Govender (white shirt) and her parents and mentors, Charmaine & Dale Godden, exhibited at the KZN Manufacturing Indaba

Industry 4.0 technologies in Africa’s manufacturing milieu AFRICAN manufacturers are aspiring to raise their standards to increase efficiency of their enterprise operations through the comprehensive uptake of sophisticated technology such as IoT and IIoT (Internet of Things and Industrial Internet of Things, respectively). Dynamic, techsavvy industrialists are resourcefully making use of innovative technology solutions to achieve improved quality control and an efficient supply chain, consequently shifting the status quo of the sector. To discuss the rising prevalence of technology within the industrial realm, the KwaZulu-Natal Manufacturing Indaba held from 14-15 August, educated participants about the opportunities and challenges associated with the adoption of innovative technology in the manufacturing sector as well as how these revolutionary capabilities can lead industrialists to yield high-quality outputs. However, the challenge here lies in the fact that the greater part of African manufacturers lacks the necessary funding to engage in such innovative undertakings. In this regard, solid collaboration between African governments and the private sector can make the process of adopting technology more accessible to a wider spectrum of industrialists across the continent. The KwaZulu-Natal Manufacturing Indaba accommodated industrialists with an extensive technological knowledge as well as those who lack proficiency in this arena. Attending manufacturers with minimal digital know-how were able to acquire the vital foundations from which to gradually infiltrate relevant digital solutions into their business operations. Exclusive debates also focussed on well-versed technological industrialists, advancing their existing knowledge base and empowering them to take their manufacturing operations to new heights. www.manufacturingindaba.co.za/mi-kzn/ Thomas Copley, Chief Technology Officer at Sumitomo Rubber presented on the latest trends relating to Industry 4.0 and IoT and how this impacts your manufacturing business PHOTOS BY LYNNE

Horst Weinert, Senior Manager: Technology Transfer, Quality Standards & Innovation at the Small Enterprise Development Agency (SEDA) spoke about Industry 4.0 Readiness Assessment

PROFILES Europe creates an interesting meeting place for professionals from the PVC profiles supply chain from throughout Europe and beyond. The primary focus is looking at developments in materials technology, production techniques, design, testing, sustainability and standards for PVC windows and other building applications such as door and decking. The two-day conference will be held from 12-13 November at the Cologne Marriott Hotel in Cologne, Germany. Dedicated sessions focus on optimising PVC compounds for construction profiles. There is an analysis of key market trends and opportunities, plus a panel discussion on sustainability and circular economy. In addition, the event explores quality control and performance testing of PVC profiles. Alongside the insightful programme, there is 10+ hours of dedicated networking breaks including the evening cocktail reception, taking place in the exhibition area. www.ami.international

Multilayer Flexible Packaging WITH plastics packaging in the media spotlight, the challenge is on for the flexible packaging industry to demonstrate not only that multilayer flexible packaging uses the fewest raw materials to provide the best protection against food waste across the supply chain, but also how they are advancing technology to improve even further. Consumers are concerned with environmental issues, but how far are they willing to give up the convenience and range of choice to which they have become accustomed? Leading companies across the multilayer flexible packaging supply chain will share how they are addressing some of these challenges at the 12th edition of AMI’s Multilayer Flexible Packaging conference, takes place from 18-20 November in Vienna at the Austria Trend Savoyen hotel. www.ami.international

Polymers in Footwear Conference

ASKEW

The third edition of AMI’s Polymers in Footwear Conference, taking place from 19-20 November, at the Sofitel Hotel Kurfürstendamm in Berlin, Germany. The high-level international two-day conference brings together polymer and additive suppliers, compounders, processing machinery experts, testing companies, shoe designers, and manufacturers to explore the wide range of existing and emerging materials and manufacturing technologies for producing footwear of all types. www.ami.international OCT / NOV 2019 93


BOOKS

Africa has highest potential market for polymers Injection moulding accounts for the greatest volume of African polymer demand A NEW report from AMI Consulting, ‘Polymer demand in Africa’, published in July 2019, has unveiled the scale and growth prospects of African polymer demand. The report makes clear that Africa represents one of the least developed but highest potential markets for polymers in the world today. Fundamental megatrends such as population growth, a burgeoning middleclass thanks to income per capita growth and rising urbanisation rates give rise to a strong growth outlook for the region. In addition, government policies such as greater infrastructure investment, economic diversification strategies and the prospect of greater FDI driven in part by the development of special economic zones, offer a favourable backdrop. The relative immaturity of the market and the amount of room to grow offers a

94 OCT / NOV 2019

New biobased polymers IDTechEx examines the key manufacturers of biobased polymers and production methods and capacities, in their report, ‘Biobased Polymers 20182023: A Technology and Market Perspective’. LyondellBasell, in partnership with Finlandbased energy company Neste, has announced the first parallel production of biobased PP and biobased LDPE at commercial scale. An initial production run has successfully resulted in the production of several thousand tons approved for use in food packaging. The polymer itself is marketed under the brand name Circulen. An independent third party tested the polymer products using carbon tracers and confirmed they contained over 30% renewable content. With the industrial production of biobased PP, IDTechEx projects that the market size for biobased polymers will be 2.7 Mt by 2023.

www.idtechex.com/en/research-report/biobased-polymers-2018-2023/618

vast opportunity for those willing to take the risk. Indeed, only a few countries in Africa have large plastic processing sectors and many import substantial volumes of plastic goods. A comprehensive investigation of market segmentation has revealed that injection moulding is the processing technique which accounts for the greatest volume of African polymer demand, with the main application being preforms sold to converters to make plastic bottles. Indeed, demand for bottled mineral water and soft drinks has increased exponentially due to the ban of thin single-use plastic in many countries and the recyclability of PET bottles. Plastic water pouches have proven to be a litter and pollution problem that many governments have acted strongly against by imposing

Opportunities, challenges for composites in future aircraft AS the commercial aerospace sector prepares for a new round of major programme launches, the question of where and how composites will be applied weighs heavily on the supply chain. CompositesWorld has released a special edition titled ‘Next-Gen Aerospace: Advanced Materials and Processes’. In it you will find reports on a variety of materials and processes targeted toward the coming wave of commercial aircraft programmes expected to be announced by Boeing, Airbus and others. Topics include resin infusion of wing structures, resin transfer moulding of door surrounds, advances in thermoplastic composites and more. Find out more at:

https://www.compositesworld.com/ opportunities-challenges-for-composites-in-future-aircraft/

single-use plastic bans. As a result, PET is the polymer seeing the fastest growth in demand in most countries. Specifically, the report examines the consumption of 14 polymers by 10 processing techniques in 20 countries. Data is provided for 2017 and 2018, with forecasts for 2019 and 2023. In addition, the division of end-use applications for each polymer, country and processing technique is provided for 2018. The report also reveals the locations of all polymer producers in Africa and capacity expectations to 2023.

• For further information contact Astrid Aupetit, senior research analyst at AMI Internationl, astrid.aupetit@ami.international www.ami.international/cons/prod.aspx

How plastics value chain can reduce plastic waste TOMRA Sorting Recycling has published an eBook, ‘The Plastic Vale Chain’, which shares transformational ideas for reducing plastic waste throughout the plastics value chain. The free eBook focuses on what we do with plastics after use, and how plastics re-enter the circular economy. TOMRA’s eBook identifies many of the actions that need to be taken to prevent environmental catastrophe. Moreover, it flags-up the necessary actions by all key industry stakeholders in the plastics value chain. Download your copy of the eBook at:

https://solutions.tomra.com/plastic-value-chain-ebook


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Maguire WSB-240 central gravimetric blender/vacuum material conveyor system for up to 400kg/hr • System can blend up to four granular free-flowing materials • Slide gate restrictor achieves accuracy to maximum of 1% variation • Hopper materials drain chute • Quad vacuum pump 3.0 kW singlestage side channel pump to convey materials to four material receivers Price available on request

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

Covestro delivers first ever order of PU resin for wind blades COVESTRO and its partners are pleased about the first commercial use of a polyurethane resin for the manufacture of wind rotor blades in China. Covestro delivered its first commercial order of PU raw materials for wind blades to TMT in China, for the production of 18 polyurethane wind blades, each 59.5m long, as well as for the spar caps and shear webs. To ensure successful deployment, the Covestro wind power team produced a prototype of the wind blades which has passed static and fatigue tests. The prototype was put into trial operation at a wind farm in central China in 2018.

www.covestro.com

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SPORTS

X-Swift

BASF advanced material innovations in latest footwear technology BASF, Longterm Concept, and Gu Guoyi have collaborated to develop X-Swift a newly designed athleisure shoe that showcases four outstanding BASF advanced material innovations fused into one shoe with the latest footwear automation technology. The X-Swift is collaboratively designed by renowned footwear designer Gu Guoyi and BASF’s Creation Centre. The design is also multi-purpose; allowing individuals to wear the same pair of shoes to work, and their next work-out. Each of the advanced and high-performance material solutions from BASF in the athleisure shoe complements each other. • The outsole made of Elastollan TPU incorporates a high grip tread pattern to optimise traction and provide maximum surface contact. • X-Swift’s midsole features the high rebound polyurethane Elastopan for excellent cushioning and durability, which is superior to conventional midsoles. • The midsole is complemented by a unique, breathable insole made of Elastopan that is engineered to work with the high-performance sock liner. • X-Swift also features an innovative, two-piece material upper construction

which is a combination of sustainable synthetic leather Haptex and fibre made with Freeflex TPU. The materials conform to the foot using minimal seams and stitch lines to provide superior comfort and maximum performance. www.basf.com

96 OCT / NOV 2019

Zero waste heel TEXON has launched Texon Halo, a new heel material for the footwear industry that contains a minimum of 50% recycled content. Developed by a team that specialises in the development of eco-friendly, structural solutions for shoe production, Texon Halo is a highperformance, powder moulded, reinforcement material that has excellent sustainability credentials and delivers distinct and measurable performance advantages. Designed for use in athletic and sports shoes, Texon Halo is ideal for creating thinner, lighter shoes with a robust yet supportive, well fitting heel. Delivered ‘out of the box’ (against dxf pattern) ready for insertion, Texon Halo is a net, waste-free product that requires no cutting or skiving. Offering good mouldability and a low heat activation point, the material is cost effective, quick to use and easy to insert. Self-adhering at lower process temperatures, Texon Halo bonds well to all commonly used substrates including synthetic materials. It is also excellent at retaining its shape over time.

www.texon.com


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The Home of Size Reduction The Home of Size Reduction The Home of Size Reduction Classifieds Feb/Mar'18.indd 92 Classifieds Oct/Nov'19.indd 92 92 Classifieds Feb/Mar'18.indd

2018/01/29 12:33 2019/09/26 12:15 2018/01/29 12:33