IndustrySA December 2013

DEC

2013 ISSUE 16

Super-Regional Retail The Baywest Mall, set to open in 2015, is beginning to take shape in the Eastern Cape.

Construction of the mall is the first phase in the wider Baywest City development set to take place over the next 15 years on its 320 hectare site in Port Elizabeth. Gavin Blows of Abacus Asset Management, one of the company’s behind the development, tells IndustrySA more about the projects progress.

Sindile Xulu Excited about the Royalty Soapie Awards

Lona Citrus International export specialists

Sunspray Food Ingredients The leader in food ingredient spray-drying

Tufbag Holding the top spot

#BeInspired

Every month we discover awe-inspiring stories of successful entrepreneurship, world-leading innovation and universal inspiration.

In the future we will bring you further stories of business excellence and highlight the hard work that is going on in South Africa to grow the nations industries into global leaders.

Your success is our inspiration

EDITOR’S PAGE

EDITORIAL EDITOR Joe Forshaw SUB EDITOR Lauren Grey WRITERS Colin Renton Tim Hands Roland Douglas Christian Jordan RESEARCH DIRECTOR Chris Bolderstone PROJECT MANAGERS James Clark Ajuanne Payne Janis Billington Leslie Kemp ADVERTISING SALES SALES DIRECTOR Andy Williams SALES MANAGER Daniel Marshall SALES EXECUTIVE Holly Graham SALES EXECUTIVE Mark Leonard STUDIO STUDIO DIRECTOR Martyn Oakley OFFICE MANAGER Tricia Plane ACCOUNTS Mike Molloy, Jane Reeder ECP LTD MANAGING DIRECTOR David Hodgson OPERATIONS DIRECTOR Chris Bolderstone FINANCE DIRECTOR Scott Warman Ferndale Business Centre, 1 Exeter Street, Norwich, NR2 4QB If you would like more information about ways in which IndustrySA can promote your business please call +44 1603 618000 or email info@industrysa.com East Coast Promotions Ltd does not accept responsibility for omissions or errors. The points of view expressed in articles by attributing writers and/or in advertisements included in this magazine do not necessarily represent those of the publisher. Any resemblance to real persons, living or dead is purely coincidental. Whilst every effort is made to ensure the accuracy of the information contained within this magazine, no legal responsibility will be accepted by the publishers for loss arising from use of information published. All rights reserved. No part of this publication may be reproduced or stored in a retrievable system or transmitted in any form or by any means without the prior written consent of the publisher.

Welcome to issue sixteen...

There is one type of technology that has been stealing the headlines at trade shows around the country recently and although it is something that has been around for decades, it still seems to amaze people and make them smile.

This technology is 3D equipment. Everything from TV and cinema to mining software and, as we are seeing more every day, printing. South Africa is a front runner in 3D technology and this is demonstrated by Triggerfish Studios, a Cape Town based animation studio whose 3D movie Khumba, has received international praise from critics. Then there is Aerosud, aerospace specialists who announced that they will build the biggest and fastest 3D printer in the world, capable to manufacturing components for aircraft, in partnership with the CSIR. This month, we explore all of these 3D innovations and more and of course, we have the usual mix of inspirational and innovative companies telling their stories of success. We speak to andalusite miners, Imerys SA, about their potential expansion into Africa; we speak to Lona Citrus about their industry leading export organisation and also, we find out more about construction of the Baywest Mall in P.E. Finally, this month IndustrySA said goodbye to one of its most talented employees, sub-editor Lauren Grey, who leaves for new pastures. While we are all sad to see her go, we are sure that she will find success in her new career.

Get in touch with us on Twitter (@industry_sa) to find out how we can promote your company’s story of success.

Joe Forshaw

editor@industrysa.com

© East Coast Promotions Ltd 2013

DEC 13 PAGE 3

CONTENTS

20

3 EDITOR’S PAGE Technology is the key

6 NEWS All that’s happening in South Africa 10 EnTREPRENEUR Animating SA

12 Innovation The new style of manufacturing 14 High-tech SA Working in the third dimension 16 Gadget Box Mining in 3D? 18 Sindile Xulu The Royalty Soapie Awards

PAGE 4 DEC 13

CONTENTS

26

20 Bay West Mall

68 DCD Wind Towers

Opening in 2015

Upliftment in the Eastern Cape

26 Imerys SA/Rhino Minerals/Samrec

76 Beekman Canopies Getaway Reader’s choice

28 Waste Legends

80 G4S South Africa Acquiring Deposita

Recycle, Re-use and Reduce

34 Marley Pipe Systems 50 years at the top

42 Lona Citrus International export specialists

50 Tufbag Bagging the industry’s top spot

56 Sunspray

84 SME Lightning Protection and Earthing 90 Bearing Man Group On the acquisition trail 94 Gross & Co Protecting your company’s greatest asset

Fine food ingredients

62 Maxe Stainless Steel

98 Industry Recommended

Tough to the max

This month’s showcased organisations

COMPANY REPORTS

Number one in andalusite

DEC 13 PAGE 5

NEWS All that’s happening in South Africa

South Africa develops the ‘smart glove’ A South African innovation, the smart glove, developed partly at the University of Cape Town is currently being tested in India on leprosy patients.

The ‘tactile’ or smart glove tracks pressure points on the palms and fingers and helps prevent injuries to hands and digits as a result of nerve damage and sensory loss. It is currently being tested at the Leprosy Mission Hospital in New Delhi.

About 95% of people are naturally immune to leprosy, caused by mycobacterium leprae, which results in progressive damage to skin, nerves, limbs and eyes.

Leprosy does not cause body parts to fall off, although they can become numb or diseased as a result of secondary infections as the disease compromises the body’s immune system.

Though curable thanks to multi-drug interventions, those who develop the disease are prone to nerve damage.

Patients often suffer a ‘secondary tier’ of injury and disability because they cannot feel heat or pressure from objects they come into contact with.

Dr Sudesh Sivarasu, a lecturer in biomedical engineering in the Department of Human Biology at the University of Cape Town (UCT), believes in developing simple biomedical solutions to problems like these.

Sivarasu took an off-the-shelf fabric glove to model his own - a stretchable glove that uses a revolutionary fabric with built-in nanosensors.

“We’ve created an artificial sense of touch,” he told UCT’s Moday Monthly. “The fabric picks up haptic factors like roughness, temperature, pressure, and humidity.”

“Because of wound infection, the digits are the first to go in leprosy patients and amputation usually follows,” said Sivarasu. “We want to make this glove widely available.”

The glove also maps how a person uses their hand to establish where the pressure variations are during simple domestic activities, such as cutting wood or cooking.

These are recorded to show where ulcers are likely to develop.

Could Amla be Cricketer of the Year?

The International Cricket Council (ICC) has released its nominations for Cricketer of the Year and amongst the high profile names is South Africa’s Hashim Amla.

The nomination is another high-point in Amla’s career after he was extremely successful at the South African Cricket Awards in September, where he was named Cricketer of the Year, Test Cricketer of the Year and SA Fan’s Player of the Year, and claimed the KFC “So Good” award for his unbeaten 311 against England last year.

The ICC also named the South African batsman in the test and ODI teams of the year.

The ICC Awards shortlist was announced in Mumbai last month by ICC CEO, Dave Richardson. The Awards will be presented as a television show on 14 December.

Three other South Africans - AB de Villiers, Dale Steyn and Vernon Philander - feature in the Test Team of the Year along with Amla. Steyn was named in the team for a sixth time in succession, while it was De Villiers’ fifth time running in the team, Amla’s fourth, and the second in a row for Philander. De Villiers is also part of the ODI Team of the Year.

Amla faces stiff competition from the likes of England’s James Anderson and Alastair Cook, Australia’s

PAGE 6 DEC

Michael Clarke, India’s MS Dhoni and Sri Lanka’s Kumar Sangakkara.

He was also nominated for the ICC Test Cricketer of the Year Award and will face fellow Protea Dale Steyn, Anderson, Clarke, and India’s Ravi Ashwin and Cheteshwar Pujara for the honour.

De Villiers and Amla are ranked one and two in the test batting rankings, while Steyn and Philander are one and two among test bowlers.

NEWS

Airbus gives large contract to South African firm One of the world’s most recognised names in the aerospace industry, Airbus, has announced it will give a large contract to South African firm Aerosud for the production of fuselage linings, cockpit linings, galleys and wing tips for the full lifespan of its A400M military transport aircraft programme.

It is reported that Aerosud, who supplies parts for Airbus’s A320 family of aircraft and A350XWB long-haul airliner, won the contract in open tender against a number of bidders from other nations.

Airbus delivered the first of a batch of 50 A400M military transport planes to the French Air Force in October. South Africa is one of a number countries working on the A400M programme.

“I am happy to re-affirm Airbus’ commitment to South Africa and its aerospace industry,” Airbus vice-president for international co-operation, Simon Ward, told the media at a briefing in Pretoria last month.

“Today Airbus-related work is the main contributor to the sector by value, and probably by volume in terms of the sheer number of parts manufactured here for our programmes. We have contracted work with local industry worth about R4-billion. Last year alone, the value of Airbusrelated manufacturing in South Africa was worth around R350-million.”

Trade and Industry Minister Rob Davies also spoke at the briefing and said that the award demonstrated South Africa’s ability in highly-technical manufacturing and the international communities growing confidence in the country’s aerospace industry.

“The aerospace industry is a strategic one, one characterised by significant levels of value-addition and technology intensity,” Davies said. “Because the global industry is heavily concentrated with complex supply chains in which suppliers have to meet the highest global standards, it is safe to state that it’s not a small achievement for a South African company to have become part of this supply chain.”

Aerosud has benefited from the Department of Trade and Industry’s (DTI’s) Aerospace Industry Support Initiative (AISI), which helps local aerospace companies to meet international standards, develop and commercialise new technologies, and gain international exposure.

Davies said the DTI had, through the AISI and the National Aerospace Centre programme, provided industry investment and skills development support worth R27 million to 169 organizations in 2012.

He added that the contract would provide sustained work, high-tech jobs and export revenues for South Africa, suggesting that successful military transport aircraft programmes tended historically to run for over 50 years.

© Airbus Military 2013 DEC 13 PAGE 7

NEWS All that’s happening in South Africa

SA’s business schools are Africa’s best

University of Cape Town The University of Cape Town’s Graduate School of Business and the University of the Witwatersrand’s Wits Business School in Johannesburg have been named top ‘emerging global schools’ in the Middle East and Africa in a survey of the world’s top business schools released last month.

The University of Cape Town’s Graduate narrowly edged out Wits Business School in a battle for top spot and the American University of Sharjah in the United Arab Emirates and the American School in Cairo, Egypt, ranked third and fourth respectively.

The QS Global Business Schools survey interviews employers who recruit MBA graduates. The survey is the largest of its kind and includes responses from 4318 employers.

The survey includes 200 business schools around the world.

UCT and Wits both fall into the second highest “emerging global” category. “These are schools which can boast an established reputation for excellence beyond their region,” the survey says.

A report following the survey said: “Though these two top business schools in Africa cannot yet match the more glamorous names of the ‘elite global’ category, it is expected that they will move up in the years to come.

“There are many more business schools across the African

PAGE 8 OCT 13

continent, but management education is still in its infancy and it will take many years before these schools achieve real prominence on the international stage.”

The survey shows that graduates from the UCT can expect to enjoy post-MBA salaries of around R840,000; among the highest in the world and the highest in the African region. With this kind of earning power, UCT can already compete with the elite global business schools, the report says.

The survey shows that UCT’s graduates, three quarters of whom are South African, are among the world’s top earners, “with the average salary three years after graduation comfortably exceeding $130,000”.

In comparison, the report finds salaries at the world’s top business schools in the US and Europe average about $123,000 including bonuses.

UCT has had a number of high points recently, most notably when its business school was the only African business school to make the inaugural “Which MBA?” ranking featured in The Economist in August. This ranking is designed to assist prospective Executive MBA (EMBA) students in choosing a programme best suited to them. It is also the only MBA programme in Africa listed in the Financial Times Top 100 Global MBA ranking.

NEWS

German firm in SA solar deal Juwi AG, a German renewable power specialist, has landed its biggest ever solar contract in South Africa.

The company, headquartered in Wörrstadt, will provide engineering, procurement and construction services for an 86MW solar park in Prieska, Northern Cape.

Juwi will be working with Sonnedix, an independent solar power producer based in Amsterdam, which landed the contract as one of six solar projects awarded in the third round of South Africa’s Renewable Energy Independent Power Producers Procurement Programme (REIPPP).

Sonnedix’s South African partners include Mulilo Renewable Energy and Ixowave Women in Power.

Known as the Mulilo Sonnedix Prieska PV solar park, it will be larger than any PV plant currently on line in Africa, and will be Juwi’s fifth project in South Africa.

Under the government’s Integrated Resource Plan, a 20 year projection on electricity supply and demand, about 42% of electricity generated in South Africa will have to come from renewable resources. The Department of Energy’s REIPPP, introduced in August 2011, will help meet this target.

“We are proud to be preferred EPC contractor for one of the six solar PV projects within the third round of the Department of Energy’s REIPP Programme. We will not only be the EPC contractor, but will also be providing the operations and maintenance,” said Greg Austin, juwi South Africa’s Managing Director.

He continued: “We are delighted to, once again, be playing a key role in adding substantial amounts of renewable energy to the South African electricity grid.”

Olivier Renon, Sonnedix South Africa Country Manager said: “We appreciate the fact that juwi has global experience as EPC contractor and local experience of building and synchronizing previous solar projects in South Africa.”

Juwi Renewable Energies in South Africa has a goal of ‘100 % clean energy, security of supply, and independence from energy imports’.

To date, juwi has erected around 730 wind turbines with a total capacity of around 1500MW and has constructed 1500 solar power plants with a total capacity of around 1350MW. Combined, these energy systems produce around five billion kilowatt hours of clean energy per year, equalling the annual demand of around 1.4 million German households.

OCT 13 PAGE 9

Entrepreneur

How animated is your CEO? Editorial : Lauren Grey Starting his career at Triggerfish Animation Studios as a stop-motion animator, Stuart Forrest thought he had landed his dream job. However, this was just the start for the entrepreneur who went on to take over the company and launch the Triggerfish brand into international success.

Award-winning entrepreneur and business owner, Stuart Forrest became a partner in Africa’s leading animation studio in 2004, before eventually taking over as CEO and re-launching the Triggerfish brand as a long form computer graphics facility in 2007.

“The company was founded as a stop-frame boutique studio in 1996,” explains Forrest, “I became a partner in 2004 and the company was wound down shortly after, with the original owners leaving. We sold off our assets but I kept ownership of the Triggerfish brand, running it from home in addition to my web design business.”

In order to develop the company, Forrest started by borrowing money from banks, family and friends, before recruiting four business partners who together were able to fund the company. The state-of-the-art studios are now situated on a newly restored farm in the leafy suburbs of Constantia, Cape Town.

PAGE 10 DEC 13

Triggerfish Animation Studios was originally established as a boutique stop-frame animation studio, which made its name by creating some of South Africa’s most memorable commercials, as well as animation for the local version of US educational program, Sesame Street, known as Takalani Sesame.

With over 40 minutes of animation, the Takalani Sesame project is still the largest international animation project ever awarded to a South African company. Triggerfish directed and produced all the material, coordinating ten animation studios across South Africa.

Building on its success, Triggerfish was then commissioned to produce animation for the U.S. version of Sesame Street, and during a period of six years, the company completed animation for three seasons of the local show, and four seasons of the US show.

“We spent ten years working on kids animation for US preschool giant Sesame Street and we completed two 12-minute shorts and one half hour short for various other clients. During

Stuart Forrest

this time we perfected our film technique and pipeline development as well as our confidence,” Forrest told Kate Douglas, howwemadeitinafrica.com.

After a successful 13 years in the animation industry, Triggerfish leapt onto the world stage with its first feature film, Adventures in Zambezia, and its second film, Khumba following closely behind.

Adventures in Zambezia, which was screened across approximately 70 countries, received international acclaim when it was screened at the Annecy International Animated Film Festival, and won Best South African Feature Film at the 2012 Durban International Film Festival.

Khumba however, surpassed the success of Zambezia after being chosen for screening at the Toronto International Film Festival earlier this year, and was one of only five children’s movies selected for screening.

The success of Triggerfish positions South Africa as a strong international contributor in the media and

entertainment industry, and is testament to Forrest who was named Innovator of the Year in the Sanlam/Business Partners Entrepreneur of the Year Competition 2012.

Forrest envisions the company as a world-leading media and entertainment company, producing original content with a unique voice direct from the heart of Africa. In order to achieve this vision, Triggerfish is evolving rapidly and has just opened a Labs Division, responsible for launching digital products.

“We are completing our first eBook and are negotiating a music publishing deal for the soundtrack of the movie (Khumba). We want to produce creative content and entertainment based on our stories and films on all the major platforms,” he told Kate Douglas.

In order to raise the bar for animation skills and world-class storytelling, Triggerfish is also in the process of establishing its own animation training facility which will help develop a first-class creative team with the ‘best writing talent available’ according to Forrest.

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DEC 13 PAGE 11

Gadget Box

3D printing now life changing Editorial: Joe Forshaw 3D printing is moving into the mainstream and changing the way we manufacture our goods. In South Africa, there have been significant developments in the 3D printing industry and we look at two stories that demonstrate the importance of 3D printing and the effects it can have on our daily lives.

3D printing is different from 3D technology in a cinema or research environment as the process actually produces a three dimensional object rather than just an image that appears three dimensional.

Critics of this type of technology (also called additive manufacturing) claim that as 3D printers become more popular, they will kill traditional manufacturing industries but many think that 3D printing will simply make important manufacturing easier, cheaper, faster and more convenient.

Although 3D printing has been around since the 80’s, it has only been over the last few years that it has come to the fore, with people seemingly amazed at the speed and simplicity of how objects appear in front of their eyes.

While 3D printers have been used for important manufacturing processes in areas including dental, automotive, military, engineering and fashion, their potential often goes unnoticed by the general public who tend to only see the printers producing plastic heads or teapots. That was until last year when South

PAGE 12 DEC 13

African aviation specialists, Aerosud, announced plans to build the world’s largest and fastest 3D printer capable of producing aircraft components. The prototype is being put together with the help of the CSIR’s (Council for Scientific and Industrial Research) National Laser Centre and it has been said that if the innovation proves to be successful it could save airlines millions on manufacturing costs, produce less waste, and use less energy than traditional manufacturing methods.

The project is so exciting that international aviation giant Airbus recently got involved stating that it wanted to test the prototype’s ability to fabricate large, complex aerospace components.

Airbus and one of their chief engineers, Bastian Schafer, have been working on concepts for an airplane that will revolutionise the air travel industry and it is said that large parts of it will be ‘printed’. The design is still only an idea and is not set to be anything more until at least 2050.

So how does 3D printing actually work? Well, using the guide of a digital design, the printer will lay down successive layers of a certain material to match the

Gadget Box

©MakerBot digital design. Materials can vary and are dependent on the machine but often liquid, powder, paper or sheet materials are used.

Wouter Gerber, Aerosud’s Project Leader; Process Development said last year that the prototype would be ten times faster than any equivalent machines available and would be able to produce components 46 times larger than anything other metal-based 3D printers are able to produce.

While Aerosud’s advances with 3D printing technology are impressive, they are not the only South African’s who have been wowing the global 3D printing industry. In 2011, a South African carpenter, Richard Van As, was working at his home when he lost control of his table saw and severed two fingers on his right hand, mangling the other two at the same time.

While in hospital Van As became determined to fix his hand so he could work again and on his release he immediately began investigating the mechanics and expenses behind prosthetics. After teaming up with an overseas partner, Van As found that 3D printing presented the cheapest and most viable option for

prosthetic manufacturing and eventually, after a lot of idea sharing and Skype calling, Van As developed a working mechanical finger.

During the development of his finger, Van As was approached by a woman who asked if the technology had the potential to help her son who was born without fingers on his right hand. With 3D printing, Van As had the capability to explore and found that the most difficult problem was the design as manufacture now took only 20 minutes thanks to the 3D printers which had been supplied by MakerBot from the USA. After refining ideas and arranging for the perfect fitment, Van As developed a working mechanical hand for the boy which responded to his wrist movements and allowed him to pick up small objects. The hand became known as ‘Robohand’ and Van As has now gone on to publish the designs and help many families to solve their own problems using 3D printing technology.

Developments have moved quickly and the latest version of Robohand can be printed very quickly and snapped together with minimal fuss, costing only around R50 for materials.

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DEC 13 PAGE 13

SA Cinema

3D cinema: not just a fad Editorial: Lauren Grey

South African 3D animated film, Khumba had its debut at the Toronto International Film Festival earlier this year and was one of only five children’s movies selected for screening. The film’s success identifies South Africa as a major international player in the utilisation of 3D technology, and demonstrates a global push towards a more advanced cinema experience.

3D films have existed on a small scale since 1950 and have, until recently, been regarded by some as a gimmick. However, recent enhancements in technology have allowed media production companies to produce flawless pieces of 3D cinema, changing perceptions dramatically.

Much like Imax, which has been utilising 3D technology for over 30 years, 3D films offer audiences a more stimulating and life-like experience; a collaboration of film and theatre, according to American film director, Martin Scorrsese.

“What I discovered working with 3D, was that with the right performances and the right moves, it enhances the actor. It’s almost as if it’s a mixture of theatre and film,” he told engadget.com.

“We see in 3D, we see in space... most of us do. Space is part of our lives. It means something. I think, for the individual person who has a vision of telling a story through images, how that person uses space - that extra element, that extra dimension - to tell a story is very, very

PAGE 14 DEC 13

important.”

South African leaders in 3D animation, Triggerfish Animation Studios, received huge support for its latest 3D film earlier this year, after it was one of only five children’s films to be selected for screening at the Toronto International Film Festival (TIFF).

Khumba, the company’s second 3D animated film, depicts the story of a zebra with only half of his stripes; the animation was bought by three major international independent distributors; Australia’s Transmission, UK’s Kaleidoscope and Italy’s Eagle Pictures.

Triggerfish CEO, Stuart Forrest told the National Film and Video Foundation that industry response to the film had been ‘tremendous’, “we’ve been able to secure significant meetings with people that we wouldn’t have been able to access just a couple of years ago. A festival like TIFF lends credibility to any filmmaker and is a great endorsement to the skills of the Triggerfish team.”

The Cape-based company mastered the art of the technology with its first 3D animated feature, Adventures

SA Cinema

in Zambezia.

Although Zambezia was not selected for screening at the TIFF, it was the highest-grossing South African film in 30 years, generating over R281 million at the box-office worldwide.

As a nation, South Africa has its finger on the pulse of industry innovations and in order to keep ahead of advancements in 3D technology, Durban’s University of Technology launched the country’s first educationorientated three-dimensional (3D) film-production laboratory in May 2011.

The lab is equipped to produce full-length 3D feature films and advertisements, as well as provide a 3D training facility for the university’s video technology students and international and local production companies, studios and TV stations.

The lab has helped to develop South Africa’s local

media production industry and further enhanced users understanding of 3D technology, which will eventually lead to the establishment of many more successful local companies like Triggerfish.

With two world-class animated features in its portfolio, Triggerfish is a major player in the development of South Africa’s local film industry and hints at an exciting future for the country within 3D film technology.

Khumba was released in South Africa in both English and Afrikaans on 25 October, before rolling out in more than 40 territories worldwide.

The country’s leading cinema chains, Ster Kinekor and Nu Metro, both now have a number 3D screens across their portfolio and with an emphasis on value-adding in cinemas, this could be the perfect way to appeal to the modern generation of movie fan.

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DEC 13 PAGE 15

Gadget Box

Mining in 3D Editorial: Roland Douglas

Developing a 3D model of an underground cavern, tunnel, mine or drill hole is now a vital part of the mining industry as it improves efficiency and safety.

Today, it is easier, quicker and cheaper than ever, and with all the new types of software available, there is an application for almost every type of exploration.

Being one of Africa’s largest industries, mining is understandably up-to-date when it comes to technology. We have featured a number of innovations in the past that have changed the way the mining business works, making things safer and more efficient and, of course, 3D technology is being used here too.

Modern software applications, developed by companies such as Maptek Vulcan, GOCAD, Leapfrog, Micromine and MineSight, use 3D modelling to provide highly accurate planning tools that are helping all aspects of raw mineral research. This is not just popular in South Africa; 3D mining software is huge business in all parts of the world and places like Australia, the USA, Canada and Chile have thriving 3D software businesses, dedicated to serving the mining industry.

Mine planning software first came to the fore in the 70’s as the gold mining industry became increasingly important to national economies and wasteful mining was not acceptable so mining houses began to develop computer programmes that could help them with efficiency. Eventually, most of the software development

PAGE 16 DEC 13

was outsourced to third parties including universities and commercial computing specialists and 3D software became important as the environmental impact of new mines is now more closely scrutinised than ever before.

The graphical element offered by this type of software holds the key to its success and obviously the 3D components offer a more in-depth idea about the geology and make-up of certain areas. Most of today’s modern graphical technology used in 3D mining software is based on well-established programmes such as OpenGL (SGI), DirectX (Microsoft) or Java (Sun). This means a more standard, stable and user-friendly software, across the whole industry.

3D computer graphics, or 3D models, are essentially mathematical representations of any three-dimensional object and the process of forming a computer model of an object’s shape is called 3D modelling, a technique that can be used to create a virtual diagram of an underground mine or drill hole.

If you work in the mining industry you will know that it is not simply a case of picking a spot and drilling some tunnels; there are huge geophysical considerations

Gadget Box

Š Maptek that have to be taken into account and software like Eureka from Maptek Vulcan is one of the easiest and most advanced pieces that can help you make decisions.

It brings all areas of exploration together to view a bigger picture in finer detail. It uses seismic, magnetic, gravitational, aerial photographic, terrain map, GIS data, historical plan and drilling information to create detailed plans of sites so that research and exploration becomes easier and safer.

So how is a 3D graphic of a certain area actually built?

The technology used is similar to the sonar radar used in a boat or submarine where a pulse of sound is emitted and the echoes are measured to determine distance between the boat and the seabed. In a mine, sound or light (sometimes lasers) is used in the same way. With a Lidar (remote sensing technology), lasers illuminate targets and when the light is reflected it is analysed so that distances and the way the surface lies can be pictured. This has proved hugely advantageous to miners looking for progress reports as weekly or monthly scans can be taken and turned into easy to understand 3D models so that it is clear exactly how much volume has

been moved.

This sort of technology is also extremely handy in industries such as forensic examinations and crime scene investigation, automotive manufacturing, archaeology, and agricultural research to name a few.

Of the areas of 3D technology that we have looked at, using the idea to build 3D graphics for mining is probably the most consistent and long-standing platform.

There are developments happening all the time, driven mainly by the demands of the mining houses themselves.

Maptek Vulcan now offers advanced modelling tools which can detect every single ceiling bolt and automatically create a 3D visual representation. Without this, each bolt must be surveyed individually. Survey points must then be manually exported to a database and the whole process becomes more laborious than necessary.

With the mainstream applications of 3D technology now consistently growing in ingenuity and popularity, it seems certain that we have only scratched the surface of what is possible within both the entertainment and research sectors.

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DEC 13 PAGE 17

Celebrity

Celebrating a flourishing South African industry Editorial – Joe Forshaw

On 8th March 2014, the inaugural Royalty Soapie Awards are coming to the Durban ICC and SABC1. Project Director, Sindile Xulu, tells IndustrySA that the awards ceremony will be full of excitement and will act as the perfect platform for the whole country to celebrate this burgeoning industry.

Can we expect plenty of glitz and glamour from the Royalty Soapie Awards?

Does the impressive list of nominees across all the categories suggest that there is currently a boom in local talent?

Certainly, this event will be a night of glamour, entertainment and celebration.

Yes, the talent in South Africa is overwhelming and platforms such as these awards ceremonies celebrate the vast talent that this country has to showcase. At the same time, these ceremonies also promote healthy competition amongst peers allowing our country to grow.

Is it a relief to finally have a fixed date for the event?

As a team we are relieved to have finalised the date and we will focus our energies on producing a top-class event that reflects the excellence of the work done by South Africa’s burgeoning television soap industry. The date coincides with the awards season overseas so we are happy with our timing.

Why was the Durban International Convention Centre chosen as the host venue?

What have been the main challenges involved in organising such an event?

The Durban ICC is a world-class venue in a fabulous eventing city. The Durban ICC promises to roll-out the red carpet and the best infrastructure that the venue has to offer for this prestigious event.

As a start-up event for the genre, securing buy-in has been challenging. Fortunately, most stakeholders have invested into the idea because it’s novel and has mass consumer appeal, for now we are focusing our energies on producing a top-class event.

Is there scope for expansion in the future, perhaps more categories or more public voting?

What sorts of entertainment can guests at the event and viewers in their homes expect?

We have an exciting show planned for the 8th of March with top class entertainment. Expect drama and spectacular performances. Be sure to tune into SABC1 to catch the awards ceremony.

What do you think the two exciting hosts will bring to the show?

Hlomla Dandala and Michael Mol are class acts and they have infinite experience in front of and behind the camera.

They will bring panache and sophistication – a true reflection of the show.

PAGE 18 DEC 13

Yes definitely, as the industry is continually growing, the awards will reflect that growth too.

Who are the judges and what does the judging process involve?

The judging panel comprises individuals with an affinity for the arts and experts in the TV production industry, photographers, actors, TV and radio personalities and entertainment media.

The process goes like this:

1. Each judge watches up to three episodes per entry in the category they were selected to judge.

2. They submit scores on a manual entry form and send the

Royalty Soapie Awards

form to the organising committee.

3. The scores are sent to independent audit firm KPMG. 4. The auditors then tally up the scores and determine the finalists and the winners.

5. The names of the finalists are revealed first.

6. The auditors have sealed the names of the winners. It will only be released at the final announcement ceremony.

Do you hope that this awards ceremony will act as a blueprint for future events?

Yes we do. This is a way for us to celebrate the genre in its entirety. This is a different ceremony to the other TV awards.

These awards are specific to the soapie industry.

How did you become involved with the Royalty Soapie Awards?

My expertise lies in project management – I’ve been involved in executing various awards of this magnitude in the past, such as the METRO FM Awards and more recently, the SA Sports Awards. I’ve also been called to assist with managing crises in events and conceptualising new ventures.

With the RSAs, Winnie Modise met me at the METRO FM awards last year and she asked me if I would be keen in realising her vision of the Royalty Soapie Awards

Finally, who will you be backing in the ‘Most Popular Soapie of the Year’ category?

.

I’m backing absolutely every one of these soapies. The talent in this country and on our screens is overwhelming. I’m happy I won’t be the one to decide.

You can vote for your favourite soapie by sending an SMS with the name of the show to 33017.

The nominees are: 7de Laan, Binneland, Generations, Inkaba, Isibaya, Isidingo, Muvhango, The Wild, Villa Rosa and Zabalaza. For more info head to www.royaltysa.com.

DEC 13 PAGE 19

CompANY PROFILE

The Baywest experience Editorial: Lauren Grey Production: Chris Bolderstone

Construction on the Eastern Cape’s Baywest Mall is well underway, with work on its earthly foundations complete; the mall is central to the development of the greater Baywest City project and is set to add to the city’s rich diversity of attractions. IndustrySA speaks to Gavin Blows of Abacus Asset Management, one of the co-developers behind the build.

Construction at one of the Eastern Cape’s most exciting developments to date commenced earlier this year, much to the delight of the local community.

At its site in Port Elizabeth, the new super-regional shopping centre, Baywest Mall is set to be a catalyst for the entire Baywest development, enhancing the lives of both residents and visitors to the area.

Estimated at R1.7 billion, the mall is the first phase of the Baywest City project, a development set to take place over the next 15 years which will see a mix of retail malls, office parks and residential nodes developed on its 320 hectare site in Port Elizabeth.

The Baywest City Project has been dubbed a “city within a city” and will offer residents a new way of living in a more pedestrian friendly environment; upon completion the development is set to be worth more than R6 billion.

PAGE 20 DEC 13

Also included in the Baywest development are hotels, private schools and associated sports facilities, a hospital complex, a motor city and a light industrial precinct, as well as a lifestyle centre.

Gavin Blows, Managing Director at Abacus Asset Management, a co-developer on the Baywest project says that it will have an “extremely positive long-term effect” on the construction industry.

“Baywest is set to have an extremely positive long-term effect not only on the construction industry in the province, but also on other sectors such as tourism and retail. Over the next 15 to 20 years, Baywest City will grow into a R6-billion development,” Blows says.

FACILITIES Covering a whopping 80,000m², Baywest Mall is set to house 250 tenants on two floors, including national chain stores,

BAYWEST MALL

international brands and an entertainment centre with 12 cinema screens.

Blows says that out of the 250 tenants, “85% are major national retailers”, and that many of the tenants for its retail outlets have already been secured, including Game, Ster Kinekor, Truworths, Edcon Group, Woolworths, Pick n Pay and Checkers.

However Blows says that negotiations with other major national and multinational retailers are still ongoing.

The mall’s design team, DHK Architects have created a technologically advanced, modern layout; making every effort to impact as minimally as possible on the environment, by making the most economical use of space, geography and the other immediate natural surroundings.

The mall aims to change the face of shopping and lifestyle in the Eastern Cape with its design, blending a retail component with a strong sense of community.

Co-developers of the mall, Abacus Asset Management and Billion Group were awarded one of the largest ever property development sums by Nedbank Corporate Property Finance in order to begin construction of the mall.

Construction giant Murray and Roberts were appointed main contractor for the project due to its reputation for good workmanship and its capacity to deliver large developments on time. Much of the team that built Cape Town’s Canal Walk shopping centre are part of the Bay West Mall construction, which is said to be a similar size.

“We are extremely excited about this project,” says Blows. “Port Elizabeth is one of the last regional retail opportunities available and this asset class has proven over many years to be the best performing in the property sector.

“Construction commenced in May this year and is on track to be completed in March 2015, according to the construction programme. Structural decks are being

DEC 13 PAGE 21

CompANY PROFILE

PAGE 22 DEC 13

BAYWEST MALL cast and structural steel work for the mall’s roof is being manufactured. Earthworks are substantially complete.”

Although the development is forging ahead, Blows says that it experienced some challenges in its early stages, “Floods in Port Elizabeth in 2012 caused a delay in contractors getting onto site, and earlier this year we had to battle wildfires,” he says.

“Despite these issues, we have managed to conduct a thorough environment reconciliation of the site, harvesting and/or relocating any sensitive and rare flora and fauna through the services of independent environmental experts.”

ABACUS ASSET MANAGEMENT Baywest Mall’s co-developer, Abacus Asset Management was established in 2006 after brothers-in-law, Jaco Odendaal and Neels Howard got together with Chris Beech from CJ Beech and Associates (Pty) Ltd. The three businessmen formed the company, which now boasts 100 years combined experience in the property development, building and financial management industries.

Abacus encompasses the vital skills to encourage the

right design, producing high quality properties and delivering on time within the budget constraints.

Blows says that Abacus and co-developer Billion Group decided to embark on the joint-venture because of how similar they are, “Both companies offer a similar product, which is why they decided to joint-venture on this exciting project,” he says.

Together, the two have over 25 years’ experience specialising in retail, commercial and mixed-use developments located in major South African cities.

With regional shopping centres, landmark office towers and golf course developments, the developers have successfully completed malls such as Hemingways in East London, Eikestad Mall in Stellenbosch, Cape Gate in the Western Cape and Mooi Rivier Mall in Potchefstroom.

Subsequent to the continuing success of the Baywest project, Blows says that the co-developers are always looking for future projects in which they can join forces, “Both Abacus and Billion are continuing to investigate development opportunities within all aspects of the South African construction industry while focusing on the growth of the Baywest City precinct.”

Curvent International is a technology driven company that has been proudly servicing our industry since 1984. We are ventilation and fire ventilation specialists able to design, manufacture and install a wide range of ventilation systems to demanding specifications that will satisfy performance, aesthetics, economics and environmental specifications.

Our head office is situated in Boksburg, Gauteng, South Africa and comprises of a 2500m2 workshop and office complex. Our coastal regions are serviced by our branch office situated in Blaauwberg, Cape Town and comprises of a 600m2 workshop and office complex.

Our operations incorporate a state-of-the-art production automation system linked to ISO quality control. Research and development technology is planned on Solid Works 3D modelling and the product is manufactured using Computerised Numeric Control machines, completely eliminating manufacturing flaws. All our raw materials is sourced locally to limit supply delays.

Head Office:

Cape Region:

Tel: +27 (0)11 826 5959 Fax: +27 (0)11 826 3275 75 North Rand Road, Hughes, Boksburg, 1459 P.O. Box 26662 East Rand 1462 South Africa

Tel: +27 (0)21 556 0430 Fax: +27 (0)11 556 2218 5B McClaren Rd, Racing Park, Killarney, Cape Town OCT 13 PAGE 23

CompANY PROFILE

EMPLOYMENT BOOST Earlier this year, figures from the Quarterly Labour Force Survey (QLFS) were published by StatsSA, which suggested that the Eastern Cape’s construction industry had outperformed all other provinces in the first nine months of this year.

Eastern Cape economic development and environmental affairs MEC, Mcebisi Jonas said that this was largely thanks to the development of Baywest Mall, and the key performance measure was job creation in the region.

It is estimated that during the mall’s construction phase 1500 local jobs will be created, out of a total 3000 direct jobs. A further 7000 indirect and induced jobs will also be created, and upon completion, 1500 permanent jobs will be created to staff 250 retail outlets.

“It will be to the Eastern Cape what Canal Walk is to Cape Town or what Sandton is to Johannesburg. It will be a massive attraction for Eastern Cape residents, as well as a major draw card for national and international visitors, in the meantime injecting much-needed jobs and income into the local economy,” Blows says.

“With construction on track, we are confident that when the mall opens in early 2015 shoppers will want to come from all over the region for the ‘Baywest

PAGE 24 DEC 13

experience’. It’s going to be something totally unique and engaging.”

HELPING SMALL BUSINESSES Further to creating employment, the Baywest project will also have a positive effect on local small-to-medium sized during the construction phase, as Abacus and Billion Group intend to target them specifically for their services.

The co-developers are keen to get SMMEs involved in the construction phase, and recently held a workshop for those struggling with the paperwork required by law for registration. Out of 400 SMMEs registered on the mall’s database, 100 attended the compliance workshop held at the Newton Park Methodist Hall.

Headed by the project’s principle contractor, Murray and Roberts, the workshop taught SMMEs how to become compliant in terms of legislated building industry requirements, such as how to apply for letters of good standing, tax clearance certificates, and other important documents required by construction industry developers when considering which companies to sub-contract to.

SARS, the Department of Labour and Murray and Roberts were all directly involved at the workshop and gave individual speeches to the attending SMMEs. Addressing the workshop, Murray and Roberts quantity

BAYWEST MALL surveyor Loyiso Bomvana, said that local labour at the Baywest site stood at 86%, with previously disadvantaged individuals comprising 81%.

With completion of Baywest Mall set for early 2015, the Eastern Cape region is readying itself for some significant changes that will positively contribute towards the environment, local community and economic development.

.

“We are extremely excited about this project… Construction commenced in May this year and is on track to be completed in early 2015”

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OCT 13 PAGE 25

CompANY PROFILE

A mining company that can take the heat Editorial: Joe Forshaw Production: James Clark

Imerys South Africa is the holding company that owns Rhino Minerals, Samrec, Ecca Holdings and Calderys, some of the country’s most successful mining and manufacturing operations. Head of strategy and corporate services, Xolisa Mvinjelwa, tells IndustrySA about the company’s plans for African expansion.

Being one of South Africa’s largest industry sectors and one of the industries behind the historical development of the country, it is no surprise that mining attracts the attention of foreign investors. According to the Chamber of Mines (2012), the industry attracts foreign savings of R1.9 trillion or 43% of value of JSE. Companies from the world’s most powerful nations all have significant interests in South African mining operations and, even though the mining industry has faced noteworthy challenges, investment into the sector continues to roll in and benefits to the country continue to be realised.

One foreign investor who has seen, and is still seeing, the benefits of investing in South African mining is French concern Imerys.

Imerys is a world leader in mineral based specialities for industry and in South Africa the company owns various

PAGE 26 DEC 13

mines and manufacturing facilities through its subsidiary, Imerys South Africa.

Head of strategy and corporate services for Imerys SA, Xolisa Mvinjelwa, tells IndustrySA more about the company’s structure explaining that the acquisitions of Rhino Minerals and Samrec in the ‘90s were milestones for the company.

“Imerys South Africa is a holding company and it was formed in 2003 as a result of the mineral resources and petroleum development act (MRPDA) which required companies to embrace black economic empowerment,” he says.

“Damrec is a subsidiary of the Imerys Group and is based in Paris, France and Damrec owns 74% of Imerys South Africa whilst the remaining 26% is owned by Nghala Mining.

“Imerys South Africa has four operating companies, three of those operating companies are in mining and one is in

Imerys South Africa/Rhino Minerals/SAMREC

manufacturing. The three in mining are Samrec, Rhino Minerals and Ecca Holdings and the manufacturing entity is Calderys South Africa.”

Samrec and Rhino Minerals are two of the country’s leading producers of andalusite, an aluminium nesosilicate mineral, used mainly for manufacturing and refractory purposes.

“Samrec mines and processes andalusite and the mining operation is in Lydenburg, called Krugerspost,” says Xolisa.

“This mine produces K ranges of products such as K57 and K55, K standing for Krugerite.

“Their other operation is a processing plant in Limpopo which receives materials from various mines. There is a crushing and screening plant and it produces various fractions, mostly for export but also for local consumption.

“Rhino Minerals has various mines. There are two main operating mines; Rhino Andalusite mine in Thabazimbi -

the biggest andalusite mine in South Africa - and Annesley mine.

“Annesley mine has just reopened and we had to relocate a community that was next to the reserves for expansion purposes so it is almost new in a way,” he says.

The third mining operation is focused on clay and more specifically, bentonite, an absorbent aluminium phyllosilicate or impure clay consisting mostly of montmorillonite.

“Ecca Holdings mines clay,” Xolisa explains. “It has a bentonite operation in the Western Cape called Cape Bentonite. The other operation in Mpumalanga produces clays, normal refractory clay and also ceramic clay. We have a processing plant which beneficiates bentonite in Gauteng in Midrand.

“All of these subsidiaries are fully owned by Imerys South Africa.

“Damrec came into South Africa in around 1992, just

DEC 13 PAGE 27

Call today for an ecological solution to your waste management problems WASTE LEGENDS – Focussing on the 3 R’s of waste management - Recycle, Re-Use and Reduce waste wherever possible “We are a total waste management company. We deal in different waste streams including hazardous waste.

Domestic waste is disposed of at any local landfill site with necessary permits. We recycle almost all wastes generated by the mining industry thus ensuring waste minimisation. We buy and sell all scrap materials namely: scrap steel, copper, aluminium, brass, stainless steel, lead, batteries, copper cables, mining hoses, HDPE and LDPE pipes, hard hats, gum boots etc.”

Waste Legends was founded in 2000 by Damara Khoza in Lydenburg, Mpumalanga. The company was originally known as Lydenburg Scrap Metals but quickly moved from working with just scrap metal to become a total waste management company and took on the name Waste Legends.

Our Vision is: • Zero Harm to people and environment • Support and Empower local people • Ensure best service possible to the mine to show our gratitude for the business given to us Waste Legends deal with all hazardous waste including oil which is purchased from the mines, stored and then sold to Oilkol for safe disposal after which a safe disposal certificate is then passed on to the mine.

Waste Legends Address: Contact Person: 9 Chrome Street Thokozani “Damara” Khoza PO Box 8217 Tel: 013 235 3047 Lydenburg Fax: 013 235 4329 1120 Cell: 072 148 1539

CompANY PROFILE

PAGE 30 DEC 13

Imerys South Africa/Rhino Minerals/SAMREC before the elections and the transition phase. They acquired Samrec in ‘92 and Rhino Minerals in ‘99. Rhino Minerals was acquired from Anglovaal whilst both the Samrec and Ecca Holdings operations were acquired from Cullinan Holdings.”

line kilns and in the gold industry for converting gold ore so there is a link to consumption of these final products. If steel usage globally increases, it is good for our industry. We are part and parcel of these global markets and so are affected as they change.”

GLOBAL MARKETS

GROWTH FOR IMERYS

The minerals mined by Rhino Minerals, Samrec and Ecca Holdings are usually exported but some are retained and sold in domestic markets. Some of the andalusite is sold internally to Calderys who are themselves an industry leader in the production of specialist products.

“The products of the mines do not go to Calderys. Of the andalusite, 13 grades are sold to Calderys but the bulk of the product is exported. Around 75% is exported and 25% is sold locally. We have a set of customers who are in the refractories business who use these products to produce monolithics and refractory bricks.

“Calderys also play in this particular space. They will produce monolithic goods and powder for refractories and use in high temperature applications,” says Xolisa.

He is also emphasises that the mines owned by the business have long useful lives remaining meaning that there will be no shortage in production and export values should remain strong.

“All of the mines are in a healthy state of repair and have an average of 20 years remaining life.”

The real challenge for the company is the tough global economic climate and the difficulties it has caused in certain markets. However, Xolisa explains that the expansion of the Rhino Minerals Annesley mine was a tactic to combat the challenging environment.

“We are restricted by the global markets however; our intention is that of growth,” he says. “That is why we have just finished the expansion and relocation of the community at Segorong and expanded our Annesley operation. It was an old mine and the reserves were depleted. Next door, in the same mining right area, we had a community sitting on top of the reserves so we had to relocate that community to gain access to the reserves. This has allowed us to extend our reserve base by 20 years. We are here to stay and we are always looking for new opportunities and Imerys globally has an appetite for growing its businesses the only challenge has always been the global market which we are sure will improve.

“The global slowdown is partially responsible for the slow market. In addition, our products being industrial in nature, used in both the ceramics and refractories industries, are high-tech products. They can be used in the steel and iron industries to line the furnaces; blast oxygen furnaces and ladles etc. They are also used in the cement industry to

Rhino Minerals, Samrec, Ecca Holdings and Calderys can all look forward to growth as Imerys is known as the leading andalusite producer worldwide and the mineral can only be found in a handful of other countries where it is depleting quickly. The demand for monolithic products continues to grow so Imerys South Africa is looking to expand its operations and take advantage of other mineral rich southern African nations.

“Globally, Imerys is huge, operating in over 44 countries,” says Xolisa. “Its turnover is close to €4 billion, it has close to 16,000 employees and South Africa is quite a small part but it remains a very strategic component of the group because of where it is placed in terms of minerals. You can only find andalusite in four main countries - South Africa, where it is abundant; China, where logistics make it difficult to mine; France, where reserves are dwindling and Peru. It is a strategic mineral which is required in certain industries and

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CompANY PROFILE it is good for Imerys to have it in the portfolio.

“South Africa is also always a springboard to doing business in the rest of southern Africa. There has been stability in the neighbouring countries and this is creating opportunities as these countries are rich in minerals which we believe we could tap into. In the long-term, we can grow the business, through acquisitions and developments, across the continent.”

He refuses to rule any countries out saying that the expertise developed at Samrec, Rhino Minerals and the other companies under the Imerys brand can all contribute their experience to African expansion.

“From the DRC all the way down through Zambia, Botswana, Mozambique, these are mineral rich countries and it is part of Imerys global strategy to look at developing countries so it makes a lot of sense for us to be here.

“There are many opportunities for the future but for now the strategy is one of consolidating the business in South Africa and creating growth opportunities. There are specific projects that we are eyeing in southern Africa however; we need to set our base first,” explains Xolisa.

COMMUNITY INVOLVEMENT All of the companies under the Imerys South Africa brand are heavily involved in community development and upliftment and Xolisa says that the companies work with their communities in a partnership type of relationship which provides more precise benefits.

“We don’t just implement projects,” he says “we consult with communities to find out what they want and what they need. For example, we have poultry farming projects, vegetable farming projects, schools where we have built libraries and extended classrooms and entrepreneurs that we have helped to develop.

“We had around eight youths who were unemployed and we put them into learnerships where they could learn to construct houses and electrify houses. When they completed the learnerships we helped to the set up their own construction companies and as we speak they are building houses and earning a living from that. The communities do play a key role in the businesses that we have.”

Of course, BEE legislation plays a part in ensuring businesses contribute to their communities and Imerys and all of its subsidiaries comply and work towards genuine community development.

“In South Africa, one of the key issues around retaining or being offered a mining right by the Department of Resources is requirements set out in BEE legislation. This has a component of community development in it,” says Xolisa. “If you look at the mining charter for example, there are certain areas that you have to comply with in terms of community

PAGE 32 DEC 13

development and your empowerment partner must also play a role in making sure communities benefit. Our communities will be shareholders at BEE level and wherever we operate we often have social labour plans and community projects that we work on.”

It is because of initiatives like this that the future looks bright for Imerys and its subsidiaries. With Rhino Minerals successfully overcoming the relocation of the Segorong community, Samrec looking to expand its capacity further and Imerys South Africa looking to draw on the skills of its established companies to expand into Africa, it seems as though this is an organisation that will undoubtedly achieve its goals.

“We have always been the leading company that produces andalusite. There is a competitor in South Africa but that is small compared to us. We continue to hold the number one position globally for mining, producing and marketing andalusite,” concludes Xolisa, who is confident that Imerys South Africa and its 700 employees are in the best place possible.

Imerys South Africa/Rhino Minerals/SAMREC

Meet Xolisa Mvinjelwa: “I’ve been with the company for around 14 years, I used to work for Anglo American and from there I went to Anglovaal.

“Imerys got me in 1999 when they bought Rhino Minerals. At that time I was assistant marketing manager globally, marketing minerals in Asia and Eastern Europe, mainly andalusite. Since then, I have moved out of sales and through to HR in 2005. I then moved to strategic issues and policy issues and became Company Secretary for Imerys South Africa and became involved with their BEE company, Nghala Mining, where my family trust is a shareholder.

“Currently, I am head of strategy and corporate services and am responsible for business development, transformation and all mining rights and related issues.”

OCT 13 PAGE 33

CompANY PROFILE

Celebrating 50 years at the top Editorial: Lauren Grey Production: James Clark

South Africa’s leader in plastic pipes and fittings for reticulation systems, Marley Pipe Systems achieved its 50th anniversary this year, but the company has been holding off celebrations in anticipation of a recently successful acquisition which is set to take them to new heights of product and service delivery.

General Manager of African operations, Michelle Harding says that the company is preparing to mark the occasion in 2014.

South African manufacturer of plastic pipes and fittings, Marley Pipe Systems, was founded in 1963 as part of the Marley SA Group; with the initial purpose of manufacturing and distributing plumbing products to the local merchant trade.

However, driven by its success and superior product quality, the company is now recognised across the globe as a leading name in plastic pipes and fittings, and has since branched out into infrastructure development, supplying a wide range of products to the civil, mining, irrigation and industrial industries.

After successfully establishing themselves in the infrastructure market, the company is now focused on becoming the preferred manufacturer and distributor of quality plastic pipe systems for the infrastructure and

PAGE 34 DEC 13

building markets in sub-Saharan Africa, whilst staying true to its founding principle of quality and credibility.

In order to efficiently service its expanding market share and global reach, Marley Pipe Systems has manufacturing facilities located in Nigel and Rosslyn, Gauteng whilst its distribution network encompasses multiple branches and depots around the country as well as offices in Namibia, Zimbabwe and Botswana, coupled with an active export division selling into Africa, the Indian Ocean, and Australia.

INNOVATING SA Marley Pipe Systems’ vision of becoming the preferred manufacturer and distributor of plastic pipes and fittings across sub-Saharan Africa is a realistic goal that the company works to achieve on a daily basis.

Marley Pipe Systems

Marley PVC Pipes One way in which the company has secured its position at the top of the industry is through its commitment to sustainability and innovation. Marley is dedicated to manufacturing products that take environmental considerations and lifecycle sustainability into account, ultimately contributing to the preservation of South Africa’s natural resources.

Adding to its already impressive portfolio, Marley recently announced that it would begin manufacturing Weholite Structured Wall Pipe. Weholite is known world-over as the preferred structured wall pipe solution for various applications, from water distribution to gravity sewers, rehabilitation projects and manholes to marine pipeline applications.

Weholite is popular with contractors thanks to its light

weight and ease of installation. It removes the need for heavy lifting equipment and reduces risks in regard to health and safety. Also, research has shown that the service life of Weholite is 50% greater than concrete in stormwater applications, and at least 100% greater than concrete in corrosive applications.

Marley, obviously a company that is continually innovating, also announced in November that it will increase its manufacturing capacity for High Density Polyethylene (HDPE) piping and pressure systems, allowing them to offer the market additional bore sizes from 16mm up to 1000mm in diameter.

Recognised for being a high impact strength, flexible, cost-effective pipe material, HDPE is increasingly becoming the material of choice for a broad range of applications,

DEC 13 PAGE 35

CompANY PROFILE including pipeline lining and relining, pipe cracking, slurry lines, gas distribution, Trenchless Technology, chemical transportation, sewerage, water supply, submerged pipelines, and for use in Dolomite areas. The increased size ranges that Marley is now able to offer will enable contractors to meet the demands of larger projects and thereby improve the integrity of finished pipelines over time.

Supporting the company in its mission for sustainability is the Aliaxis Group, for which Marley Pipe Systems became a member in 1999.

The Aliaxis Group is the global leader of plastic solutions for fluid handling systems in residential and commercial markets as well as industrial and public infrastructure applications. The group is present in over 40 countries and focuses on innovation, quality, excellent service and value.

As an Aliaxis Company, Marley Pipe Systems is able

PAGE 36 DEC 13 Weholite Pipe

to bring reticulation solutions and new technology from around the globe to the local market in a sustainable manner, focusing on every aspect of the product lifecycle, from product design and development, all the way through to recycling waste material back into new products.

ANGOLA CUNENE WATER PROJECT Marley Pipe Systems has a variety of successfully completed projects in its portfolio, but the company’s largest contribution to a single project was the Angola Cunene Water project, in which Marley was awarded a $15 million water supply contract in Angola by Spanish company UTE Befesa-Riogersa.

This huge contract, commissioned by the Angolan Ministry of Energy and Water, forms part of the master trans-frontier plan with Namibia to supply safe drinking

water to Cunene, benefiting approximately 250,000 people who previously did not have access to fresh drinking water daily.

As one of the provinces devastated by Angolan conflict, Cunene has suffered from a lack of proper supply and sanitation systems, resulting in low levels of access to clean drinking water.

Only 15-20% of the rural population has the advantage of a dedicated water source, whilst the rest rely on walking far distances every day to retrieve unhealthy water from local rivers, boreholes, and small dams to provide for their families.

Overall, the project provided for the extraction and treatment of water from the Cunene River via a water treatment facility at Xangongo. From there, the treated water is pumped along a 100km pipeline to three different towns, Xangongo, Mongua and

“Our business strategy is to grow into Africa; we are already present in some African markets, but we hope for more than just export into these countries, we actually want to establish a footprint�

Ondjiva.

The main part of the project involved the supply of over 98km of 630mm PN6 HDPE pipe as well as about 2km of 630mm PN10 HDPE pipe.

Transporting the pipes the distance to Angola was no easy feat and the pipes had to be delivered in 15m length to decrease the number of welds on-site.

In order to ensure the safe passage of the HDPE pipes, Marley partnered with WP Transport, who had 16 trailers custom built for this project.

The trailers had specially designed uprights with cradles to ensure that the pipes fit onto the trucks perfectly and were steady and secure. Each truck transported 16 pipe lengths at a time, adding up to a total loading height of more than 2.5m per truck.

The enormity of the project presented some challenges for Marley Pipe Systems, including stringent quality control checks and rigorous customs processes at the Angolan border, but the company went above and beyond to ensure the project was completed.

OCT 13 PAGE 37

CompANY PROFILE For Marley Pipe Systems, the Angola Cunene Water project was about more than just business; it was an opportunity to uplift communities by giving them access to water; the most fundamental resource of life.

EDUCATION IS KEY As demonstrated by the Angola Cunene Water project, Marley Pipe Systems is dedicated to the broader community, and earlier this year the company sponsored a national

“We want to establish ourselves across southern Africa, and we hope to do this by opening branches, warehouses and even manufacturing facilities at different locations should the projects warrant it” water competition in a bid to educate, create awareness and encourage the youth of South Africa to follow a career as a

Marley MEGAFLEX Flexible PVC Hoses PAGE 38 DEC 13

science or civil engineering professional.

The SAICE-WRC Water Competition, known as AQUALIBRIUM, comprises individual regional competitions which ultimately culminate in a showdown where the winning teams gather in Johannesburg to battle it out for the grand prize.

In order to give students an idea of what it takes to be a civil engineer or related professional, students from each team are tasked to design and construct a model water distribution network.

The teams are given unique ‘design kits’ which are purpose-made for the competition, containing all the ‘pipes’ and ‘connections’ that the students will need to build a pipeline capable of distributing three litres of water equally between three points on a given grid.

As part of its commitment to this valuable project, Marley Pipe Systems sponsored in excess of R50,000 to SAICE for the development of 30 new and complete kits.

In a statement, Marie Ashpole, Outreach Officer for SAICE, emphasised the importance of industry support to make this valuable project happen.

“Without industry, this competition would not be possible – it’s fantastic to have companies such as Marley on board to help get our message across as a united industry and to encourage the youth to get into the civil engineering

BAYWEST MALL

Delivering Value packaging

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pulling and cutting

and much more for pipes

www.sica-italy.com OCT 13 PAGE 39

CompANY PROFILE

Marley uPVC & mPVC Pipes

profession and related industries.”

FUTURE PLANS Since establishing its first facility 50 years ago, Marley Pipe Systems has grown organically throughout South Africa, offering innovative solutions within the plastic pipe and fittings market, and going forward, the company hopes to expand its operations throughout Africa.

The company currently exports its product across the continent, but is looking instead to establish a physical presence in these countries, as General Manager of African operations, Michelle Harding explains.

“Our business strategy is to grow into Africa; we are already present in some African markets, but we hope for more than just export into these countries, we actually want to establish a footprint.

“We want to establish ourselves across southern Africa, and we are planning to do this by opening branches, warehouses and even manufacturing facilities at different locations should the projects warrant it.”

Marley Pipe Systems has also just completed the acquisition of leading pipe manufacturer Petzetakis Africa,

PAGE 40 DEC 13

which is now part of the Marley Group, expanding the company’s exposure within the mining and civil engineering industries.

The company acknowledges this acquisition as a huge step forward and something to celebrate, which is why it intends to mark the occasion, along with its 50th anniversary with a series of road shows taking place next year.

“We will have a media release and a road show for the South African market, celebrating the acquisition and the 50th anniversary. This will happen early 2014,” says Harding.

.

“Without industry, this competition would not be possible – it’s fantastic to have companies such as Marley on board to help get our message across as a united industry and to encourage the youth to get into the civil engineering profession and related industries”

BAYWEST MALL

“more than just a chemical supplier”

OCT 13 PAGE 41

CompANY PROFILE

The benchmark in citrus

Editorial: Christian Jordan Production: James Clark

Cape Town based Lona Citrus has been exporting quality South African citrus for the past 17 years.

General Manager, Irving Davelaar, tells IndustrySA that the company is committed to working with local farmers to continue to raise the profile of this important South African export.

Now is a good time to be operating in the South African citrus industry. The South African product is highly desirable in international markets and is often regarded as the industry benchmark. CEO of the Citrus Growers Association, Justin Chadwick, said in a recent newsletter: “The soft citrus sector exported a record 8.4 million cartons in the 2013 citrus export season,” suggesting that the demand for the product in foreign markets remains strong.

For most farmers, getting their product to international markets requires a reputable exporter. Fortunately, there is a company that is partnering with citrus growers across the country and assisting with the development of their farms and distribution of their product. That company is Lona Citrus and General Manager, Irving Davelaar tells IndustrySA that Lona was in fact started in a garage in Cape Town.

PAGE 42 DEC 13

“The company was started in 1996 preceding the chaotic deregulation of the export industry and up until that point Capespan was a single channel distributer and getting an export license was very difficult,” he says.

“Our founder and MD, Spencer Johnson, spoke to a few farmers and realised there was a large degree of discontent about the way business was being conducted in the industry so he started a marketing company in his father’s garage with a R30,000 loan.”

In the early days, the company was not only a citrus exporter but focussed on a range of different fruits and vegetables. However, Davelaar says that this made it difficult to give full attention to each commodity as the seasons overlap.

“As export volumes increased, Spencer recruited a few more people to manage logistics, marketing, procurement and other functions across all the commodity groups.”

Lona Citrus

“At the end of 2002, a management decision was taken to focus on Citrus. At this point citrus was doing very well and covered 70% of the commodities being traded. Obviously, domestically, it is geographically well spread so it limits risk when it comes to natural disasters, macro-economic impacts, pests and diseases, and fruit flies etc. Also, from an international marketing point of view, the market is huge. It spreads from Canada right across to Japan and this is why the company decided to divest from everything else we were doing and focus more on citrus. From then on we became a citrus export specialist,” he says.

“A milestone in Lona’s history came when the company decided to integrate into primary agriculture in 05/06,” says Davelaar.

“We invested in our first farm and this gave us further credibility with the likes of retailers such as Tesco, Sainsbury’s and Marks and Spencer. This gave the company

a sustainable advantage as it was now seen as a grower and exporter/trader supplying to some of the largest retailers in the world.

“We have since invested in a couple more farms, to secure the sourcing of the fruit and gain more control of the supply chain. We are involved in all areas, from the farm all the way to export. In-between that we help farmers develop; we finance them, we aggregate their fruit and then we export it.

This has given the company solid ground to stand on.”

PREVIOUSLY DISADVANTAGED Early on in Lona’s life, the business had a simple set-up, purchasing fruit from local farmers and exporting that fruit.

However, today the set-up is very different. Lona, either fully or partially, owns five farms – two in the Limpopo, two in the Eastern Cape and one in the Western Cape.

The company’s product portfolio is complimented by

DEC 13 PAGE 43

CompANY PROFILE input from independent farmers and also farms that it manages and mentors.

“Of our total product” says Davelaar, “we own around 20%, we get 50% from independents and 30% comes from farms that we manage and mentor and these are previously disadvantaged farms.”

Through the Land Redistribution Programme farmers have received land with a lot of potential for citrus growing but the hand-over wasn’t always done correctly with sustainability in mind. There is a lack of skills and knowledge and this has been hampering progress.

Fortunately, Lona offers assistance in numerous areas.

“Lona has played a big role over the last nine or ten years in mentoring these farmers. Assisting and facilitating these farmers in the process to obtain the relevant knowledge such as what fertilisers to use, when to use them, how to plant trees, how to manage admin and finance etc.

“The main areas that farmers need support with is admin and finance. There is often a lack of paperwork, audit trails and the knowledge of financial management.

It’s very admin intensive on our side and it’s important to act in an advisory capacity and not boss people around. It’s a challenge but it can be very interesting and it’s amazing, the feeling you get when you’ve been working at it for a

PAGE 44 DEC 13

couple of years and you see the improvement on the farms because of your input,” explains Davelaar.

The impact of Lona on these farms is clear and evidenced in the statistics, especially the number of cartons exported. Davelaar details one example in which, thanks in part to Lona, the producer was able to increase their output by 430,000 cartons.

“We have seen massive changes, sometimes in just a short amount of time,” he explains. “For example, there is a farm in north that we got involved with. In the beginning they were exporting around 20,000 cartons of citrus. In 2010, they did around 450,000 cartons. This improvement was over just four years.”

Of course this is not the only example of the value that Lona brings to its partners. All of the relationships that the company has built have seen positive results.

“In the Eastern Cape, we’ve seen the same thing,” says Davelaar. “We partner with a group of farmers, the Landbank and the IDC where we do all of the ground work to get these growers up and running and this year for the first time they broke the 100,000 carton mark. An increase from 70,000 cartons in 2012 to 180,000 cartons in 2013. Exceptional achievements, considering some of these farms were not even producing just a couple of years ago.”

No matter whether the fruit comes from an independent

Lona Citrus

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grower, a Lona farm or a farm that the company is partnering with, Davelaar emphasises that the most significant factor is quality.

“The quality of the fruit is what’s important to us. If it’s top quality we can send it to more attractive markets like the Far East and produce a better return for the grower.

It doesn’t matter which of the farms it comes from, if it’s up to quality standards then it is consolidated with similar quality fruit and it goes to the customer,” he says.

LOCAL & INTERNATIONAL Being an export focussed company, Lona obviously has its finger firmly on the pulse of all of the important international markets but, interestingly, the company is keen to expand into the local market in South Africa and build its presence in the valuable African market.

“We do operate in domestic markets but it’s a negligible amount at the moment,” explains Davelaar.

“Domestic markets are different to export markets. In export markets, you pack the fruit at the pack house and send it to the cold store which is the central distribution point at either Durban, Port Elizabeth or Cape Town. So that’s a limited amount of high-volume locations to manage.

“Everything that doesn’t make it to export is for the local market and stays at the pack house. Now you would have to coordinate the 40-50 farms and pack houses and get the product to a central distribution point and then get it to a retailer so the logistics and coordination with local markets is a little more complex but it’s something that we are definitely looking into. We are trying to partner with a couple of local players and looking at the other African markets as well but it’s something that’s developing.

“Logistics is expensive an often the infrastructure is not there so it’s an on-going process.

“There are a billion people to the north of us, that’s a billion person market right there. It’s definitely something we are pursuing but there are a lot of macroeconomic and socio-political issues to navigate on top of infrastructural constraints,” he says.

While citrus will remain the focus for exports, the company may diversify as it makes inroads in domestic markets.

“In the local markets we may look at some level of diversification from the products we farm, but in terms of exports, our intention is to stay focused on citrus,” says Davelaar.

DEC 13 PAGE 45

CompANY PROFILE

PAGE 46 DEC 13

Lona Citrus

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CITRUS SPECIALISTS

Irving Davelaar

Over the 17 years of its existence, Lona has become an industry leader, not just in the citrus farming market but the export market more generally. Davelaar explains that today Lona is one of the leading export companies of fresh produce in the whole country.

“We focus on citrus so that is quite specialised and quite niche. If we look at the market, we are the fourth largest exporter, when it comes to citrus, in South Africa and we are the eighth largest company in the export industry and that’s all commodities included. “Lona remains privately owned and is one of the largest citrus exporters in the industry.”

Being an organisation of size, influence and experience, Lona uses its position in the market place to great effect when it comes to social initiatives. Its work with developing farmers and community projects is admirable and Davelaar says that upliftment is embedded in the culture of Lona.

“In Limpopo and the Eastern Cape there are significant challenges and this happens to be where our two biggest farms are located so we are trying to build the businesses that we engage with in those provinces so that we can continue to develop the rural economy sustainably.

“Citrus farming is very labour intensive but in order for people to be able to work, they have to be able to leave their

DEC 13 PAGE 47

CompANY PROFILE children somewhere and that is the idea behind one of our day care facilities funded through the Fair Trade program.

Employees know their children are going to get fed and educated and this allows them to balance their life. It’s not something we see as an obligation; we see it as a necessity.

“Internally, we have a slogan – you work at Lona, you change lives for the better. We are very passionate about building up the economy because there is a lot to be done, especially in rural areas as the government alone cannot do this,” he says.

THE FUTURE There is huge scope for expansion for a company like Lona.

Increasing their involvement in the farming process, entering new markets, potentially increasing the product range – there are many options available but Davelaar suggests that the focus will be on the markets in the Far East as well as strengthening relationships with current farmers and developing new relationships with new farmers in the South African market.

“We would like to take a balanced approach to international markets. We separate them into three main segments; Canada and the UK and Europe, Russia and the Middle East, and the Far East.

“If you look at the demographics of the world, you would be short-sighted not to increase focus and strengthen one’s presence in the Far East with its large consumer base.

However we do want balanced exposure in all markets.

“We would definitely want to partner with the Development Finance Institutions like the Industrial

PAGE 48 DEC 13

Development Corporation, Landbank, Department of Rural Development and Land Reform, Development Bank of South Africa and the Public Investment Corporation to be a key development partner in their economic development strategies as we have a good track record,” he says.

How is the company able to consistently build on its impressive track record? Davelaar puts the on-going success down to a commitment to both customers and producers.

“We fight to get the best returns for our producers and we fight to keep our customers happy. There is a fine balance between the two.

“We see the producers as one of us and we place huge importance on the customer because if you have no home for the product you have nothing.

“We manage to consistently find a balance between the two and that is one of our key success factors,” he says.

Without doubt this is a company that will be at the forefront of the market, raising standards and setting benchmarks, for some time to come. And, of course, behind all the fantastic work is the people and Davelaar concludes by saying that Lona has the best.

“We have a passionate group of people who are in the industry because they want to be, not because they have to be.”

.

“We have a passionate group of people who are in the industry because they want to be, not because they have to be”

Lona Citrus

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Johannesburg Durban Cape Town

OCT 13 PAGE 49

CompANY PROFILE

This one’s in the bag Editorial: Christian Jordan Production: Chris Bolderstone

Tufbag is one of South Africa’s industry leaders when it comes to flexible intermediate bulk containers and as we move into 2014 the company is investing in order to grow. Managing Director, Gareth Jelliman tells IndustrySA more…

What is your solution when you have to move large amounts of dry, flowable products? Have you ever actually considered this problem? If you are a mine you will have, or if you are in agriculture or food production or road construction, moving heavy amounts of flowable product can represent a logistical and functional nightmare.

With a new mine for example; you cannot just pile up your excess earth creating mountains by the side of your site. And with agriculture, you cannot move enough fertilisers to cover 100 acres of land in an open skip, you need a strong, flexible, reliable solution that is going to protect and manage your goods.

The answer is flexible intermediate bulk containers (FIBC), bulk bags or jumbo bags. Unlike metal, wooden or plastic containers, bulk bags can be easily transported and stored when not in use and they still provide the strength and sturdiness to keep your materials contained and safe.

In South Africa, one of the leading suppliers of FIBC is

PAGE 50 DEC 13

Tufbag, a family run company based just outside Durban.

Recently, Tufbag Managing Director, Gareth Jelliman told IndustrySA that even during tough economic conditions and a challenging economic climate, the company has managed to perform extremely well with October being one of the most successful months in Tufbag’s history.

“2013 has been a year of change and with change has come its challenges,” he says “but our future looks bright and prosperous with October 2013 being one of the most successful months in the company’s history.”

RESTRUCTURING Tufbag has a long and complicated past and in 2013 the business added another milestone to its history when it restructured, joining two industry leaders namely Multi Tarp and Bag and Jel-Ex. “Tufbag as is today is the joining of two rival companies that dominated the FIBC bulk bag industry in South Africa for the past 30 years,” says Jelliman.

Tufbag

Multi Tarp and Bag was started in 1986 by Bryan Jelliman and Jel-Ex was started in 2001 as an extrusion and weaving company, also owned by Bryan Jelliman and Tufbag, a company owned by Norman Cook, started in 1982. In 1988, Tufbag was bought by Nampak, one of the country’s most prominent names in packaging. In 2006, Raffia Holdings bought Tufbag, which was now fully integrated, and renamed the company Raffia Tufbag. This changed in 2010 when the Bryan Jelliman Family Trust bought the shares in Raffia Tufbag and dropped Raffia from the name, reverting back to the company’s original name, Tufbag. “Tufbag is now South Africa’s single largest bulk bag and underground mine support manufacturer,” says Jelliman.

As we move into 2014, Jelliman says that the past 12 months have been about bringing together the cultures of the business that have merged. “2013 has been a year of rationalising of the various business units,” he says.

“The single biggest challenge has been the merging of

two arch-rivals and the management styles.”

The joining of the two companies will help achieve the goal of becoming a partner to companies across many different industries as Jelliman explains.

“Tufbag is a proudly South African organisation, aimed at supporting local industry. We are looking at being the manufacturer and supplier of choice for our clients, adapting to their needs and building partnerships within their businesses, always adding value.

“The majority of our business is in the sugar industry thanks to our geo-graphical positioning. We also service industries including fertilisers, mining, milling and chemical.”

QUALITY PRODUCT Tufbag’s products are some of the most popular on the market, and for good reason. FIBCs are most often made of thick woven polyethylene or polypropylene, either coated or uncoated and come in a range of sizes. Their

DEC 13 PAGE 51

CompANY PROFILE capacity is normally around 1000kg but the larger units can store even more. The average bulk bag, made to ship one metric ton, can weigh between 2-4kgs on its own.

“Currently, we have the capacity to produce 2.1million bulk bags and 1.5million underground mine support bags per annum. Annually, we convert 7,500 tons of polypropylene polymer into our products,” says Jelliman.

The company produces a diverse range of bags suited to various products in different industries.

“Our bulk bag is the core of our business, with the OMEGA bulk bag being our flagship product. We also specialise in form stable bulk bags namely SquarePack bulk bags, single point lift bags as well as the internationally patented Tellap bulk bag which integrates a pallet into the bag,” he explains.

Clearly, this is not a company that plugs a round hole with a square peg. For every requirement, there is a different solution and even as customers come up with new and different problems, Tufbag strives to come up with cost-effective, innovative products and Jelliman suggests that the company has already started planning for meeting the demands that will arise in 2014.

“We are always extremely busy with new products; our

research and development team are always looking for new ways of producing our products more efficiently and reducing costs to clients. Our product is a technical product and requires careful consideration to safety, so with that in mind we use our world class laboratories based at each manufacturing site to aid us in these developments.

“New markets for Tufbag, without giving away too many secrets, would be a new food grade approved manufacturing facility and some exciting niche products that we will release into the market in early 2014. More information about all of these products will be available on our new website www.tufbag.com, set to launch soon.”

These fantastic products that serve ‘hard to please’ markets are produced by Tufbag’s 1200 strong workforce and, in-partnership their clients, the company utilises its first class technology to produce what Jelliman calls “world class products”.

“We are a strong player in our market and we have the single largest extrusion and weaving plant in South Africa, using the most advanced machinery available to our industry from Europe, with Starlinger of Austria as our machine supplier of choice, a company of who we have had a long standing relationship with, enabling us to offer world

“Striving for Greater Heights” J.J. Logistics is a diverse and uniquely structured transport company based in Ladysmith, KZN. We currently have a fleet of 20 horse and trailers and 20 rigids, all servicing the whole of South Africa and our neighbours in Zambia, Namibia, Zimbabwe and Mozambique. At J.J. Logistics we strive for customer satisfaction and believe that every customer is a valuable asset to us.

PAGE 52 DEC 13

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: Tufbag

"Proud to be associated with Tufbag"

OCT 13 PAGE 53

CompANY PROFILE

PAGE 54 DEC 13

Tufbag

GROWTH

So, with growth definitely on the cards and customers and markets all burgeoning, Tufbag has placed itself in an extremely strong position. Jelliman concludes by telling us that focus on customers, staff and targets are what makes the company a triumph.

“The key to our success is hard work, and dedication to our customers and closely working with our staff in order to achieve our desired goals.”

To date, Tufbag has been a considerable success and is now widely regarded as an industry leader. However, the company is not happy to sit back and is continually planning its next project.

“Our annual growth is estimated at 6% and the fact that our product are extremely labour intensive means we will always draw on the local community to supply labour for our various processes,” explains Jelliman.

“We are busy with various 2014 capital expenditure projects at the moment, two completely new and top secret, and one being a new blown film extrusion line to supply our plant with polyethylene film. This project has been on the cards for many years as it is the last phase in our total vertical integration project.”

“Tufbag is a proudly South African organisation, aimed at supporting local industry.

We are looking at being the manufacturer and supplier of choice for our clients, adapting to their needs and building partnerships within their businesses, always adding value”

class products made locally.

“We are extremely conscience of imported products threatening our local industry and rely heavily on our service levels to counter these threats, but working closely with our clients we are able to offer the best solution for their application.”

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OCT 13 PAGE 55

CompANY PROFILE

Fine food ingredients Editorial: Lauren Grey Production: Chris Bolderstone

Sunspray Food Ingredients, South Africa’s largest producer of spray-dried food products has been operating within the local market for more than fifty years. However, the company’s biggest milestone came in 2006 when Managing Director, David Watson sold off half of the business and diversified its product range.

Sunspray Food Ingredients was formally established in 2006 by Managing Director, David Watson who – after 62 years of trading under the Nutritional Foods brand - decided to reinvent the company and diversify its product offerings.

Nutritional Foods was originally founded in 1944 as a South African manufacturing and marketing company, aimed at producing powdered foodstuffs for refugees.

In 1957, the company’s first spray drying tower was erected on its site in Industria, followed by a second tower in the 1960’s; this allowed the company to expand its product range, entering the instant coffee market, and by 1970 Nutritional Foods had become the first company in South Africa to produce coffee creamers on contract for other companies.

Subsequent to its growing success, the company further enhanced its product range in 1980 when it purchased

PAGE 56 DEC 13

Clifton Manufacturing (Pty) Ltd and entered the consumer product market for the first time; manufacturing powdered soft drinks, soya-based soups and stews, milk blends, hot chocolate drink powders and desserts.Furthermore, in 1998 Nutritional Foods purchased Funa Foods, doubling its size in the catering market, and as part of the deal, acquired a modern processing plant in Klerksdorp. Following this acquisition, the company consolidated the manufacture of all its catering products in Klerksdorp, while the Industria factory concentrated on contract manufacturing and the production of spray-dried food ingredients and retail products.

REBRAND With the Klerksdorp and Industria factories manufacturing different products for different markets, it was soon decided to run the sites completely separately, and towards the end

Sunspray Food Ingredients

of 2005 a BEE company, Imuniti Holdings Ltd., offered to buy the Catering Division business.

As part of the sale agreement, the new owners acquired the name Nutritional Foods and the remaining business was rebranded and renamed Sunspray Food Ingredients (Pty) Ltd, reflecting its business activities more accurately; focusing on contract manufacturing and food ingredients with spray-drying being its core technology.

The company now consists of two divisions; its original factory at Industria and a second factory in Bronkhorstspruit, acquired in 2005 by Nutritional Foods after purchasing Ovipro, an egg processing business.

Managing Directing, David Watson tells IndustrySA more about the rebrand: “Ultimately the big change came in 2006 when I sold off half of the business, with that the Nutritional Foods name went.

“It made sense because the company had become more

and more involved with spray drying and ingredients, so I changed the name to Sunspray Food Ingredients.

“Literally, from 2006 we reinvented ourselves and have become one of the foremost ingredient manufacturers in South Africa and the leader in spray dried products.”

Watson, who has been involved in the food industry since leaving university, has a 47% shareholding in Sunspray and says that his desire to ‘do something on his own’ is what fuelled him to buy into the business.

“As I was approaching 40, I decided I wanted to do something on my own; I was able to get a Merchant Bank to back me, that’s when we bought the company. The bank still has shares but I am the biggest shareholder.”

Sunspray is now South Africa’s largest producer of spraydried products and the company services almost every food manufacturer in the country, “Worldwide there is plenty of opposition for each product line we have, but there’s

DEC 13 PAGE 57

CompANY PROFILE

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Sunspray Food Ingredients no one in South Africa that can produce the diversity of products that we do,” says Watson.

The company’s diverse product portfolio includes caramel powders, meat flavours, fat powders, creamers, fruit and vegetable powders and cheese powders to name a few.

PRODUCTION FACILITIES Sunspray has extensive manufacturing facilities spread across its two sites. On the 1.7 hectares of land in Industria, there are five production spray driers as well as a pilot plant spray drier used for research and development purposes.

Apart from the spray driers there are also extensive blending facilities in Industria and a varied range of packing equipment which enables the company to provide a comprehensive service for its clients. In support of its production facilities there is also a quality control laboratory on site manned by qualified personnel.

On the Bronkhorstspruit site, there are two main production spray driers. In addition to this an old small spray-drier has been recently commissioned in an isolated area to run products with pungent odours, such as onion

and garlic powders.

The Bronkhorstspruit site was originally designed for egg processing only, but now many other products are also spray dried on both of the towers.

Spread across both of its manufacturing sites, Sunspray has 150 full time employees, the majority of which are in manufacturing and support services such as quality assurance, quality control, logistics and engineering services.

Nearly 40 members of its staff have tertiary education qualifications and approximately 30% of its employees have been with the company for longer than ten years.

In order to cater for fluctuations in demand, particularly in the contract manufacturing division, Sunspray also employs numerous contract workers. The number can vary from 50 to 100 and currently the company is giving employment to approximately 80 contract workers. Some of the other site services such as security and cleaning are contracted out to third party service providers.

Furthermore, as part of its corporate social investment, Sunspray has contracted out all its local transport requirements to a BEE company, MK Transport, who now also handle all of Sunspray’s off-site warehousing needs.

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OCT 13 PAGE 59

CompANY PROFILE

DD WILLIAMSON Sunspray’s biggest division by far is that of food ingredients, for which all of its products are marketed by a team of marketing executives, irrespective of where they are manufactured.

The food ingredients product range is extensive and consists of meat flavours, fat powders, caramel powders, fruit and vegetable powders, citrus oil concentrates, milk blends, creamers, cheese powders, flavours (under licence) and egg powders (whole egg, albumen and yolk powders).

Apart from the main products there are also some interesting miscellaneous products such as honey powder, paprika powder, fenugreek powder, molasses, flavour carrier, cloud, vinegar powder, soy sauce powder and Worcestershire sauce powder. All of the above are spray dried and/or blended powder products.

All of Sunspray’s food ingredients are marketed under the Sunspray brand with the exception of liquid caramels which are marketed on behalf of DD Williamson, who manufacture these products in Swaziland.

Sunspray has marketed DD Williamson’s liquid caramels for a number of years and due to its excellent service, the company has recently been awarded marketing and distribution of DDW’s Natural Colours range.

PAGE 60 DEC 13

Watson says that the company’s relationship with DD Williamson has been ‘extremely successful’ and being awarded marketing and distribution of yet another product range is ‘fantastic news’.

“Apart from buying caramel liquor from DDW, we have represented them by marketing their liquid caramels within South Africa for a number of years; this got us into the beverage industry quite strongly.

“We’ve done such a good job at marketing their liquid caramels they have asked us to take on their other Natural Colours range, which we will market to both existing and new customers.”

AFRICAN EXPANSION With the inclusion of Nutritional Foods, Sunspray Food Ingredients has, in effect, been the country’s spray-drying innovator for more than fifty years. However, the company’s next big venture is expansion into the African market, which Watson says is going ‘pretty well so far’.

“We have some products particularly geared for the African market, mainly meat flavours, caramel flavours and tomato powders. Our customers in Africa produce soups and stews, and this has become a very big market for us going forward with our expansion.

“The other product we are looking to take into Africa at

Sunspray Food Ingredients the moment is cheese powder, mainly for the snack industry which is growing pretty well at the moment.”

Aside from this, Sunspray has also been involved with international exports such as its most recent venture into Europe, “We are doing pretty well in Africa as far as exports are concerned, but we have also entered the international market.

“Although our international ventures are fairly small at the moment, we are still very excited about what the future will hold for this side of the business, for example we recently did our first export of fruit powders into Europe.”

.

“Literally, from 2006 we reinvented ourselves and have become one of the foremost ingredient manufacturers in South Africa and the leader of spray dried products.”

FANCRAFT is an ISO 9001:2008 certified company, that specialize in rotating equipment.

Our services include: • Overhauls • Reconditioning of parts • Supply of new spare parts • Maintenance on all rotating equipment • Manufacturing of parts • White metal bearings • Shaft manufacturing • Laser alignment • Inspections • Problem solving • Drawings • Consulting

Tel | (016) 986-0795 / (016) 986-0796 Email | info@fancraft.co.za Fax | (016) 986-0796 Web | www.fancraft.co.za Postal Address | P.O. Box 2201, OCTSasolburg, 13 PAGE 611947

COMPANY REPORT

Tried, tested, trusted and tough Editorial: Roland Douglas Production: Chris Bolderstone

Maxe Stainless Steel produces steel components and accessories for the automotive industry in South Africa. The company is a leader in its industry and has grown tremendously over the years since its formation in 1997. IndustrySA looks at what makes Maxe such a success…

Operating in the steel industry can often be challenging for any company, with price fluctuations and supply issues to consider. The automotive industry is not much different; there are rising export costs and labour issues to navigate. Then there is the manufacturing industry more widely - again an industry which is not short of challenges; cheap foreign imports, the rise of advanced technology and, of course, the proverbial skills shortage. So, you would think that running a business that spans all three of these complex industries would be like running through a minefield but one of South Africa’s leading autocomponent manufacturers, Maxe Stainless Steel, has proven over the years that with effective management and a strong workforce, you can not only be successful in these industries but you can become recognised as an industry leader in both local and international markets.

PAGE 62 DEC 13

Maxe was established in 1997 and bought the use of stainless steel for vehicle accessories to the fore. The driver behind this was the steel nudge bar produced for the ‘97 Mitsubishi Pajero. After this accessory proved extremely popular, many other manufacturers of painted mild steel products had to rethink their strategies and product offerings to serve a newly formed appetite from buyers for stainless steel accessories.

In 2004, seven years after its inception, Maxe produced a full accessory kit for the Toyota Hilux Legend 35 and this represented a milestone in the company’s history as originally only 600 kits were ordered but in the end over 6000 were produced. The kits included nudge bar with sump guard, roll bar, side steps, rear step and a tow bar.

Today, Maxe calls a number of the world’s biggest motor brands its clients. Toyota, Nissan, General

Maxe Stainless Steel

© VW 2013 Motors, Hyundai, Kia, Daihatsu, Great Wall Motors and others all benefit from Maxe’s OEM approved range of locally manufactured stainless and mild steel accessories.

Only the finest quality marine grade 304 steel tube and plate is used for the manufacture of Maxe products and a unique Durabar coating helps to set them apart from the rest. The products are widely produced for SUV’s or LDV’s and everything comes from the company’s factory in New Germany, Pinetown near Durban. The factory is a state-of-the-art manufacturing facility with the very latest in tube manufacturing, pipe manipulation, and laser cutting machine technology.

The company moved into the factory in 2007 following a period of unprecedented growth. At the time the company was struggling to keep up with local demand and big name clients - who were building their vehicles without any bumpers, running boards or roll-

over protectors – were looking to take a slice of the autoaccessory market which was valued at R2billion in 2007.

Maxe’s factory and processes are backed up by ISO9001 certification, achieved in 2006 and still held to this day and because of this, and the company’s vast experience, customers can rest assured there are receiving the very best from one of the industry’s leaders.

The 8500m² facility was opened partly to help cope with local demand as back then the company was not exporting but previously it had dealt in various international markets. Today, with the backing of the Autovest group, Maxe is on a growth drive and may look at expansion opportunities in international markets, especially those on the African continent. Of course, business will be boosted by the fact that sales of SUV’s are again on the rise in Africa with sharp increases reported in the sale of luxury SUV’s since 2009.

DEC 13 PAGE 63

Time FreightREPORT and Maxe – A Partnership Forged In Steel COMPANY What began as a small, daily delivery for a company looking to break into the automotive industry is now, 14 years on, a strong and mutually beneficial relationship between two of KwaZulu-Natal’s most respected companies - Time Freight and Maxe Stainless Steel.

When Time Freight began moving consignments for Maxe - who were founded in 1997 and specialise in the production of stainless steel bull bars, nudge bars, bumper protectors, side steps, side bars, roll bars, and rear styling bars and steps for a range of light delivery vehicles and sports utility vehicles – their daily load consisted of 10 to 20 items.

Today, Time Freight transports an average of 4750 items per month for Maxe around South Africa. The weight of all that steel, a formidable 79 tons every 30 days.

“We were moving their products back then from their tiny premises off Circuit Drive in Westmead,” recalls Time Freight Divisional Executive Mike Burton when their partnership with Maxe began.

The company was in its infancy, but making quick inroads into the vehicle accessory sector.

With Maxe soon going into business with vehicle manufacturers like Toyota, Nissan, Kia, Hyundai, Great Wall Motors, and General Motors, their need for timely and safe deliveries became vital as their order book grew. Time Freight was an obvious choice for the vehicle accessory manufacturer.

“Maxe is a supplier to major and smaller vehicle manufacturers across South Africa and as one of their preferred carriers we value this partnership a great deal, not only as a carrier but also being involved with a company such as Maxe whose product quality and research and development is of the highest order,” said Burton.

With hundreds of thousands of parts successfully delivered during the 14-year partnership, Burton states that one of the most important aspects of maintaining their successful track record is ensuring all deliveries are carried out with “an equal amount of swiftness and enthusiasm”.

“Time Freight has always enjoyed a mutually beneficial relationship with Maxe. Yes, we’ve had our ups and downs, but we have both learnt from these experiences to the benefit of all,” Burton adds.

As both Maxe and Time Freight go from strength to strength, two constants sure to remain are their strong ties and desire to see all deliveries continuing to arrive on time.

AUTOVEST In 2007, Maxe became part of the Autovest group of companies, a specialised collection of businesses that lead the way in different areas of the automotive industry. Autovest says it “endeavours to meet customer’s requirements by providing a unique ‘one stop’ accessories shop offering a range of quality products,” and to do this they are consistently investing in, and growing, established and profitable businesses within the automotive industry.

Autovest’s company portfolio currently contains eight automotive accessory brands - Bucco Canopies, SA Canopy Centre, Rhino Linings, Kilber Products, StarTrek, Auto Armor, Auto Enhance and Maxe Stainless Steel – and through these brands Autovest positions itself as South Africa’s largest single supplier of automotive accessories sold through the OEM dealerships, with national distribution through more than 130 franchised fitment centres and the only supplier that can provide a broad range of accessories.

Autovest is a South African company and focusses on building on its strengths through the development and use of local talent. All of its subsidiaries are proudly South African and the supply chains of each subsidiary are local in every sense. In the case of Maxe, who

PAGE 64 DEC 13

are involved in everything from design through to manufacture and after sales support, all is done with local products, local people and local expertise.

Maxe was the first company that Autovest acquired after its establishment by Nedbank in 2007 but in 2011, RMB Corvest, a private equity firm and division of FirstRand Group, purchased a 28% stake in Autovest with the view of expanding the company.

Autovest’s CEO, Ted Waldbuger, said in 2011: “Although we enjoyed a successful partnership with Nedbank, they were approaching the end of their investment horizon, having been invested in Maxe prior to the inception of Autovest.”

He continued to say that the deal would help Autovest on its acquisition trail.

“We are extremely excited about our relationship with RMB Corvest, which will ultimately enable Autovest to accelerate its acquisition strategy.”

After the deal, Autovest acquired Auto Armor and launched the Auto Enhance brand, proving that the RMB Corvest investment had been of great benefit.

LOCAL BUSINESS As mentioned above, Maxe is a big player in the local market, creating numerous jobs both directly and

Maxe Stainless Steel

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COMPANY REPORT indirectly and stimulating growth in its supply chain.

Take Time Freight for example, a logistics partner of Maxe’s for 14 years. They move nearly 5000 items for Maxe every month and that translates to nearly 80,000kgs of material each month. Time Freight is a South African company with roots in KZN. Then there is the Maxe business itself; it employs over 300 people (up from 180 in 2007) and in KZN, where unemployment levels sit at just under 20% (Dec 2012), this type of job creation is extremely beneficial.

The company’s employees are highly skilled and help to build long-lasting relationships with OEMs. Maxe says that it gives customers a specific product because it is involved in all processes from initial idea through to production and installation.

“Maxe prides its self on being involved in every stage of the product development, from customer request for a specific design to implementation, manufacturing,

distribution and technical field support.

“Our Development Department has the latest Engineering CATIA Software and technical skills to design and develop a product that are to exact customer specifications,” the company’s website states.

Design is a key element of Maxe’s success and the fact that designs are tailored to the South African market with African conditions in mind helps to keep Maxe at the forefront of the local market.

Of the big name players that Maxe supplies, the focus is often on the regional division and the products supplied add value to the final product creating a mutually beneficial relationship.

The future is bright for Maxe and as we move into 2014, there are plenty of opportunities on the horizon for the company who is actively seeking expansion. In July 2013, sales of the top ten LCV’s were up by 9.2% on the same period in 2012. The top ten is made up

© Ford 2013 PAGE 66 DEC 13

Services

Maxe Stainless Steel

Entek Industrial Chemicals offer product development to all industrial products with laboratory back up.

Products and analytical services to the Metal Finishing Industrial Welding consumables, Electro polishing, Buffing products to the Stainless Steel manufacturing Industries.

Chemical treatment plants and products for powder coating industry with laboratory back up.

Powder Coating Products A leading supplier of manual, automatic powder coating equipment, automatic electrostatic powder coating gun, powder optimization equipment and powder recovery system.

Chemical treatment plants and products for powder coating industry with laboratory back up.

of numerous Maxe customers and as long as growth like this continues for the sector, there is no reason why the company can’t go on to grow even further, creating more jobs and developing the already sterling reputation of South Africa’s auto-accessory industry.

.

“Maxe prides its self on being involved in every stage of the product development, from customer request for a specific design to implementation, manufacturing, distribution and technical field support”

Physical Address:

122 Brackenhill Road Unit 2 Chestnut Grove Industrial Park Waterfall

Postal Address:

P O Box 19 Kloof 3640

Autovest companies and Maxe Stainless Steel sister companies: • SA Canopy • Auto Armor • Rhino Linings • Kilber Products • StarTrek • Auto Enhance • Bucco Canopies DEC 13 PAGE 67

CompANY PROFILE

Wind power is finally being realised Editorial: Joe Forshaw Production: Leslie Kemp

As the 23,000m2, R300 million DCD Wind Towers manufacturing facility nears completion, excitement in the renewables industry is growing and many people in the Eastern Cape are hailing the project as the start of triumph for local manufacturing. All this and the factory is still two months away from fabricating its first product…

After years of planning and development, it seems that the true potential of wind power in South Africa is now starting to be realised. The country’s

into a new substation on the site. This substation will then feed into the Fitchards Corner substation which will then feed, via the Nelson Mandela Bay municipality, into the national grid.

first commercial wind farm, The Van Stadens Wind Farm near Port Elizabeth in the Eastern Cape, started supplying power to the national grid at the end of November.

This is of course hugely exciting for the renewable industry in South Africa, an industry which has faced its fair share of challenges while getting off the ground.

Initially, just one of the Metrowind Sinovel turbines has supplied electricity but the other eight will come online over the next two months in the run up to the original target date for full commission, February 1st 2014.

Eskom will assist in getting the power onto the national grid and so far, the consensus is that this is a huge step forward for the wind industry and the Eastern Cape.

The electricity that is generated by the wind farm will feed

LOCAL IMPACT

PAGE 68 DEC 13

This is great news for the Eastern Cape, and especially the Blue Horizon Bay and surrounding areas, but there is one company who will have kept a closer eye on this news than most and that is DCD Wind Towers.

DCD Wind Towers is a subsidiary of DCD’s Mining and Energy division (featured in IndustrySA December 2012 and July 2013) and the company is very active in the renewable industry. This was demonstrated back in March when construction on a R300 million wind tower manufacturing facility began.

In July, DCD Mining and Energy Marketing Manager, Henk Schoeman, told IndustrySA that the company was investigating the possibility of amending original designs to

DCD Wind Towers

©BMG raise the potential output levels for the facility.

“The factory has been designed to manufacture around 120 towers each year. We are investigating whether or not we can increase capacity and it looks as though we will be able to increase to around 180-200 towers per year,” he said.

“The wind turbine towers will vary in size, ranging between 80 and 120 meters, with individual sections weighing between 40-60 tons.”

Since we spoke to Schoeman, work has moved at a dramatic pace and now the facility is close to completion but the impact on the local economy has proven to be more valuable than original projections suggested.

“It is important for the Eastern Cape as it will create around 600 jobs during construction and we will employ 150 operational staff when the factory is up and running,” Schoeman said.

He also said that the effect would be felt throughout the supply chain, with local businesses benefitting too, “In the

future we will create a supply chain and support smaller local companies to assist with supply of components for the factory.

It is without a doubt a great injection of work and opportunity for the local community.”

Many of the people who have benefitted from the project have been from the Nelson Mandela Bay municipality and Ayanda Vilakazi, Coega Development Corporation (CDC) Head of Marketing and Communications says that the pace of the development is down to the skill of the local infrastructure and construction specialists.

“Investors are given a choice whether or not to use Coega’s infrastructure and construction services when they decide to set up shop in the Coega IDZ,” he said in a statement.

“The pace at which DCD is going up is an indication of the quality and speed of Coega’s expert team. In addition, we are able to ensure that on projects such as these that small construction firms also gain a share of the work. The aim is for SMMEs (small, micro, medium-sized enterprises) to benefit

DEC 13 PAGE 69

CompANY PROFILE

from 35% of CDC’s procurement.”

The CDC is proud to state that so far, the materials used in the construction process amount to 236 tonnes of reinforcement, 1896 tonnes of structural steel and 8440m3 of concrete and, of course, when the facility is fully operational, it will contribute further to the provision of local content for the wind energy industry in South Africa.

HIGH-SPEC FACILITY You may think that the company has fast-tracked construction to get the factory from nothing to working in just over 11 months but you would be wrong. Obviously, safety and quality remain some of the top priorities and a number of achievements have already been gained as the factory nears completion.

During construction, the factory has gained compliance orders from Aspirata, earned more than 20,000 injury free hours, assisted SMMEs and sub-contractors with approval of their environmental health and safety files and has had minimal detrimental impact on the local environment.

CDC Infrastructure Project Manager, Bruno Ponzo, said that the goal was still to get the factory ready for February so that DCD could begin supplying to its first two customers. He also explained that the facility would not drain the national grid of all of the valuable electricity that its products will help to create as it has been put together with ‘green objectives’ in mind.

PAGE 70 DEC 13

“An example of such is the introduction of natural light shafts in the façade walls and the use of passive natural ventilation elements. The on-site offices will also make use of solar control devices and performance glazing to reinforce the aesthetic aspects of the structure,” he said.

The CDC has long been keen to position the IDZ as a centre for renewable energy projects in the Eastern Cape and hope that DCD’s investment will provide a boost in this regard.

“With DCD located in the Coega IDZ, we add impetus to moves to position the Coega IDZ as the green energy hub of the Eastern Cape. This action also enables local renewable energy component manufacturing growth in tandem with the major wind projects on track in the province and country,” Vilakazi said in a statement.

Schoeman added that as well as providing the boost for the local market, the factory would be completed with international specifications in mind so that products can also be competitive in international markets.

“A substantial amount of research and development work has already been undertaken, and the DCD Wind Towers team is benchmarking its facility on a number of similar facilities visited in Europe and Asia and, with the help of its technology partner, has designed the layout of a factory that is internationally competitive in terms of production, quality and pricing,” he said.

It is hoped that the factory will have a wide-reaching impact

DCD Wind Towers

Innovations for a global market Fall arresters redefined: Hailo PARTNER Hailo fall arrester systems are designed to prevent service staff from falling when using ladders and manhole steps, both above and below ground. Tracks or a steel rope used to guide the fall arrester are mounted to ladders and manhole steps (to one side or centrally) connected to the installation.

Hailo TOPlift LX for pylon structures Hailo service lifts have been especially developed for use in wind power systems. By deploying high-quality materials and components, the systems are suitable for long-term, safe use in virtually all wind power systems, as all fixing elements are designed and manufactured so that the Hailo TOPlift can be used for internal access in tubular towers and for external access in the case of pylon structures.

Hailo BLADElift S: rotor blade lift system for small wind power systems The rotor blades in a wind power system must be regularly accessed for cleaning, repair and servicing purposes. With the Hailo BLADElift, the company has developed a system that – as a result of its modular construction – can be customised allowing for easy inspection of both smaller rotors in 0.5-MW systems and in 6-MW systems.

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OCT 13 PAGE 71

CompANY PROFILE

on the energy industry in South Africa and as the government continues its drive towards changing the energy mix, with renewables playing an ever increasing role, the hope is that manufacturing things like wind towers, from a local base, will keep ideas, skills and money within the SA economy as well as attracting foreign investment.

INDUSTRY LEADERS When complete, the factory will cover 23,000m² of zone 3 of the Coega IDZ and produce some of the highest spec wind towers for commercial wind farms that are popping up all over the Eastern Cape and throughout the rest of the country.

In July, Schoeman told us that DCD would like to supply wind farms on the African continent, especially in the south as the logistics are easier to manage. If DCD can supply into other African nations it will prove extremely lucrative for the company as the renewable energy industry begins to blossom.

Morocco is currently home to one of the biggest wind farms in Africa, the Koudia Al Baida Farm, and more commercial farms are planned or online in countries including Kenya (Lake Turkana Wind Power), The Gambia (Batokunku), Ethiopia (Ashegoda Wind Farm) and Egypt (Zaafarana Farm).

Although DCD’s Wind Towers subsidiary is a fairly new part of the business, the company has vast experience in the wider energy sector and Schoeman told IndustrySA that it’s not just wind power that DCD specialises in.

“We manufactured products for the Ingla Hydro Power

PAGE 72 DEC 13

Station and in the past we have manufactured penstocks for other hydro stations. As a company and a group we have great experience in this sector.

“The manufacture of products for all the power stations; coal, nuclear and hydro is our focus, we’ve manufactured products for every power station in South Africa.

“DCD as a company has already manufactured the first 80 meter tower for the Aerodyne turbine which was the first locally manufactured and assembled 2.5MW turbine as a prototype in South Africa.”

Such a large build in such a short period of time has been a challenge and this was summed up by the CDC’s business development manager for the energy sector, Sandisiwe Ncemane, who said: “We have worked long and hard to create an environment in which renewable energy - from end to end could both flourish at and be facilitated by Coega.

“This is becoming a hard-won reality, as investment in this sector grows not only within the boundaries of the Coega IDZ but throughout the province.”

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“It is without a doubt a great injection of work and opportunity for the local community”

DCD Wind Towers

OCT 13 PAGE 73

CompANY PROFILE

Copyright reference of the picture: Shutterstock – majeczka

ArcelorMittal South Africa, a supplier of steel solutions for the wind energy industry ArcelorMittal South Africa is part of the global ArcelorMittal group that makes renewable energy more sustainable.

PAGE 74 DEC 13

www.arcelormittal.com/southafrica

ArcelorMittal is constantly developing new technologies which improve the sustainability of our products and business practices. We work in close partnership with our customers and suppliers to help them achieve their environmental goals through innovation in steel solutions.

As an international company with industrial operations in more than 20 countries, ArcelorMittal recognises the impact that climate change will have on many regions in which we work. That is why we are fully engaged in global efforts to reduce greenhouse gas emissions and mitigate their impact.

Steel, the green choice for wind energy As a natural, permanent material, steel is the ideal material to support the industry in supplying material to meet the ever increasing demands for energy. Steel can already be used to create more than 80% of the components required to build a wind turbine. Valued for its strength, flexibility and durability in the field, steel is also 100% recyclable, making wind energy truly renewable.

Within its first year of operation, a steel wind turbine will pay back the energy required for its production.

Wind Energy South Africa According to the Government’s Integrated Resource Plan some 17 800 MW of renewable energy is planned until 2030 of which 8400MW will be wind energy. For rounds 1 and 2, projects for 634MW and 565MW have already been allocated. This is part of the drive towards green energy and will reduce the carbon emission extensively.

Steels for every part of your wind tower ArcelorMittal produces steels which are suitable for all major parts of a wind turbine. Around 85% of all wind turbine towers are built with quarto plate steel, also known as heavy plate. ArcelorMittal is a highly respected supplier of quarto plate. One of our mills ArcelorMittal Asturias in Gijón (Spain) has supplied quarto plate for more than 3,000 wind towers since 2005. We are contemplating to upgrade our plate mill as the aim is to produce all the plates locally in South Africa, but in cases where dimensions or specifications cannot be achieved, this could be provided from within the group. The rebar required for tower foundations as well as other long products will be supplied from our mills in Newcastle and Vereeniging

Plate specifications

DCD Wind Towers

Plates from ArcelorMittal South Africa will be supplied in accordance with the EN 10025 standard using structural steel grades including S275, S355 (including JR, J0 & J2) plate can be supplied with the following dimensions: Thickness: Up to 80 mm Width: Up to 3,000 mm Length: Up to 13,000 mm (15000 mm after the proposed upgrade)

ArcelorMittal’s support adds value at all stages ArcelorMittal’s experience in the wind power sector has enabled us to develop a service programme which is specifically oriented to meet the needs of the industry.

That experience enables us to add significant value for our wind energy customer. ArcelorMittal’s global customer teams work closely with our customers to respond quickly to new and changing requirements.

The teams include technical experts, mills, marketing and sales personnel in order to ensure every possible eventuality is covered – something which is imperative in such a challenging supply chain. While our efforts have concentrated on reducing lead times between customer order and final delivery, ArcelorMittal also undertakes R&D activities in order to maximise cost savings for our customers. We can help wind energy suppliers develop and implement entirely new supply chains if required.

Creating the wind power solutions of tomorrow ArcelorMittal’s global R&D team includes more than 1,300 world-class researchers located in 11 laboratories around the world. Their experience and knowledge of steel and the wind power industry enables ArcelorMittal to support our customers and develop new solutions to meet the challenges they face. ArcelorMittal is actively working with wind power suppliers to develop the next generation of multi-megawatt tower designs using our high added value steels. With our global presence, ArcelorMittal is uniquely positioned to supply the wind industry with the steel solutions they require.

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Plate Mill at ArcelorMittal South Africa

Rebar produced by ArcelorMittal South Africa

OCT 13 PAGE 75

COMPANY REPORT

On top of the competition Editorial: Lauren Grey Production: Janis Billington Beekman Super Canopies, one of three major canopy manufacturers in South Africa, is renowned for its superior product quality and excellent customer service. The company was awarded the Getaway Readers Choice Award in 2012 in the Canopies category, and has recently made plans for its future growth strategy, IndustrySA finds out more.

South Africa’s vehicle and component manufacturing industries faced significant challenges this year, with labour strikes estimated to have caused a production revenue loss of around R20 billion at a vehicle manufacturing level.

In a press release issued by the National Association of Automobile Manufacturers of South Africa (NAAMA), President Dr Johan Van Zyl said that the strike action had damaged South Africa’s status as a reliable supplier to the international export markets.

Van Zyl also said that with vehicle and automotive component manufacturing sectors accounting for approximately 30% of South Africa’s manufacturing output, the strike would inevitably result in lower economic growth.

However, with much of the strike action settled and production lines back up and running, many companies are working hard to redeem the industry and repair the damage caused to the country’s foreign investment prospects.

PAGE 76 DEC 13

INDUSTRY LEADER Leading by example in a recently troubled industry, South Africa’s Beekman Super Canopies has shown true business excellence and reliability since inception; reinforcing the country’s capability to manufacture quality automotive components.

Established in the Western Cape in 1977, Beekman started as a family business manufacturing fibreglass vehicle canopies for the local market, it remained very much a family business until the Imperial Group obtained a 51% share in 2006, which grew to 100% two years later.

Beekman is one of three major canopy manufacturers and distributors in South Africa, with an 18% share in the market nationally, and a 37% share in the Western, Northern and Eastern Cape.

With over 400 employees, Beekman is well established in South Africa and known for products of high quality and reliability. To ensure consistent high levels of quality amongst its employees, Beekman has a MerSETA accredited training school which trains 40 people a year.

Twice a year groups of 20 unemployed people are put

BEEKMAN SUPER CANOPIES

through training in fibre-glass production processes, as well as life skills and personal finance. On qualification, the individuals receive a MerSETA certificate, and 70% of these individuals are employed in the Beekman factory.

FACILITIES Beekman manufacture and distribute 16,500 canopies a year and offers a range of 120 models which are used by vehicle manufacturers such as Mitsubishi, Toyota, Nissan and Isuzu to enhance their bakkies; providing a durable extension to the vehicle that protects cargo and adds transport capabilities.

Canopies have become increasingly popular in South Africa, mainly for storage and improved security but also because people are choosing to buy a bakkie as a lifestyle vehicle; allowing owners to use it on a day-to-day basis, but also for excursions at weekends.

Of the 80,000 – 90,000 bakkies sold annually, a large percentage are fitted with canopies, of which Beekman is a direct supplier. The company also caters for older model bakkies, as well as supplying accessories such as lights,

window tinting and bakkie lids.

Most of Beekman’s products are manufactured at its plant in Cape Town which has been awarded ISO 90012008 certification and Managing Director, Kobus Stander, says he is ‘very proud’, “We are extremely proud of our manufacturing plant in Cape Town, as we were recently awarded ISO 9001-2008 certification. All our manufacturing processes and quality controls meet international standards,” he said in a statement.

Beekman is OEM approved for leading manufacturers and works on the DSO (distribution systems operator) system and is the only canopy manufacturer in South Africa with ISO accreditation.

In the Cape, Beekman has a research and development division and a styling department, which operates in conjunction with acknowledged experts in the field, Jurgens Caravans, also part of the Imperial Group.

In total, Beekman has eight depots, one fitment centre in Randburg and 36 independent agents around the country. Its products carry a comprehensive two year factory warranty on the fiberglass shell and one year on the mechanical items.

DEC 13 PAGE 77

COMPANY REPORT

GROWTH STRATEGY Subsequent to its continuing success in South Africa, Beekman is now looking to grow its market share by establishing stand-alone sales and fitment centres, with its first in Randburg.

Business Development Manager, Chris van der Westhuizen says that the main focus is to provide on-site fitment and services to dealers and to the public within a radius of 15 to 20km around Randburg, Krugersdorp, Benoni, Bethal and Pretoria.

It is hoped that being within a close proximity to motor dealerships will help grow the Beekman brand.

“We are extremely excited about our new fitment centre concept store which we have just opened in Randburg… exciting times lie ahead. We focus on delivering exceptional quality and service” he said in a statement.

Van der Westhuizen also said that he is intent on expanding the Beekman accessory product line through the Randburg fitment centre.

Also commenting on the new fitment centres, Imperial Automotive Retail CEO, Philip Michaux told Business Day Live that he was “supportive of the initiative” and was looking at further areas for development.

“I am also supportive of the initiative to develop stand-alone Beekman Super Canopy sales and fitment centres in convenient locations and we are looking at

PAGE 78 DEC 13

further suitable areas for this type of development.

“We are always looking for new business opportunities in this line and among our recent developments are an increased range of top quality executive glass fibre canopies and the introduction of a range of very well finished steel canopies sourced from Thailand. We aim to remain at the leading edge of technology as we grow the Beekman business.”

READER’S CHOICE AWARD Beekman was recognised for its high-quality products and services in 2012, when it was awarded the Getaway Reader’s Choice award, after being selected as the readers’ favourite brand in the Canopies category.

In a statement, Beekman thanked its agents for their commitment to the brand, “We thank all our fitment centres and agents in Southern Africa for their commitment to the brand and ensuring we deliver superior product and service to our clientele.”

.

“We are extremely excited about our new fitment centre concept store which we have just opened in Randburg…

Exciting times lie ahead”

Maxe Stainless Steel

Proudly South African Founded in 1981,Howick Metal Productshas established itself as one of South Africa’s leading manufacturers and distributors of Architectural Hardware and Ironmongery, including purpose made products, to suit your requirements, in Aluminium and Brass.

By partnering with us for all your Aluminium and Brass requirements, we can work along side you to develop the correct product to increase your business performance, therefore giving you a competitive advantage in the market place. We also brand customers products with their Logo, which in turn portrays ,they only supply

quality products to the market.

Sales enquiries:

Address:

Tel: +27 (0) 33 3303 534 Fax: +27 (0) 33 330 4248

PO Box 190 Merrivale 3291 South Africa

Email: info@howickmetal.co.za Web: howickmetal.co.za

8A Saligna Road Merrivale KwaZulu-Natal South Africa SEP 13 PAGE 79

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Certified top security solutions Editorial: Tim Hands Production: Chris Bolderstone

Recently recognised as one of the top employers in South Africa for 2014, the only security company in Africa to be awarded this prestigious accolade, G4S South Africa strives endlessly to expand and develop the services it is able to offer. Its recent acquisition of Deposita, the leading provider of retail cash solutions technology in South Africa, exemplifies this desire to grow and improve, with an unerring focus on the social responsibility a company of this magnitude inevitably has.

G4S is the world’s leading international security group, and has a history dating back to 1957 in South Africa, employing over 13,000 personnel to secure its position as the largest provider of integrated security solutions in the country.

The G4S brand came about as a product of a merger between Group 4 Falck and Securicor in 2004, and nowadays the company’s experts are those who drive the security industry forward, through positive and innovative practices. Central to placing the company at the forefront of the industry is its ability to provide customers with cost effective, innovative integrated security solutions, drawing on and sharing the skills and experience picked up from its work across the globe.

G4S South Africa recognises the value of meeting fully the total security and cash management needs of its customers, which in turn allows these customers to focus their own energies on undertaking the core activities of their businesses, free from worrying about risks which may otherwise pose threats to their operations. In South Africa there are three main operating companies that comprise the group: G4S Care and Justice Services; G4S Cash Solutions; and G4S Secure Solutions.

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With more than 100 years of expertise to draw on, G4S fulfils its services with constant reference to a distinct culture, and an equally strong set of values. Always seeking to further hone and develop its expertise, this is demonstrated by the company’s tirelessly innovative and leading edge approach to creating and delivering the right solution. A focus is also placed on always employing the right people to deliver these services, in the process developing their competence, providing further opportunity, and in turn helping G4S South Africa achieve its goal of improving performance year-on-year and creating longterm sustainability. A clear customer focus engenders close, open relationships with all who benefit from these expertly delivered solutions, generating trust and ensuring that all parties work in partnership for the mutual benefit of the many varied organisations with whom G4S South Africa deals.

Its recent recognition, through research conducted by the CRF Institute, as one of the Best Employers in Africa, as well as one of the Top Employers in South Africa for 2014, is the highest validation of G4S South Africa’s provision of an engaging, safe working environment, and one in which the contribution of each employee is valued and considered. G4S is, notably, the only security company in Africa to be awarded

G4S South Africa

this accolade, which acts as a certification of excellence in the conditions that employers create for their people, as recognised and awarded by the Top Employers Institute. A number of different criteria are considered and must be met in order for this certification to be awarded, with the employers stringently assessed on primary benefits, secondary benefits and working conditions training and development, career development and culture management.

This extensive list of criteria includes most, if not all, of the ideal traits of a business for whom staff development, safety and welfare are at the forefront of its concerns, and G4S Africa were understandably delighted to be recognised with such a prestigious accolade.

Elanie Kruger, Regional HR Director of G4S Africa, expressed the company’s pride at the receipt of the award: “We are thrilled to receive Top Employer accreditation in 11 countries this year. With a staff compliment of over 112,000 people in Africa, we are the largest private employer on the continent. We recognise the importance of solid people practices and make sure we create a safe environment where our employees feel valued and are given opportunities to grow.”

Samantha Crous, Regional Director Africa and Benelux for the Top Employers Institute also spoke of G4S Africa’s commitment to its staff across the entirety of its operations: “Our comprehensive research concluded that G4S provides an outstanding employment environment and nurtures and develops talent throughout all levels of the organisation. The international recognition as a Top Employer Africa sends a strong message to their staff and all other stakeholders that this company greatly values their people and that their employee conditions are at the highest standard.”

As well as showing itself to be a company of exemplary employee conditions and talent development, late last year, G4S Cash Solutions (SA) (Pty) Ltd, already a leading provider of cash solutions in South Africa, acquired Deposita, South Africa’s leading provider of retail cash solutions technology.

Deposita has long been South Africa’s market leader in cash devices and related cash-in-transit, cash processing and insurance services for the retail sector, and its acquisition

by G4S will look to significantly strengthen its position in the South African retail cash technology marketplace. This is a sector which is forecast to grow rapidly over the next three years, and the acquisition brings with it numerous

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additional benefits to the services G4S is able to offer, such as opportunities to export this technology solution into other G4S African countries, including Botswana, Malawi, Kenya and Namibia.

Deposita itself was founded in 2004 and rapidly expanded its operations throughout the whole of South Africa. With its headquarters in Midrand, it employs 165 staff across the country, and offers customers a complete cash solution in the retail cash market. The process is one of devastating simplicity and efficacy, beginning with the process of securing and counting cash notes on premises, safely storing it on customer premises, transporting the cash to cash centres, and providing same-day settlement of funds into bank accounts.

Andy Baker, Regional President of G4S Africa described how Deposita’s, “market leadership in cash device technology, extensive client base and unmatched track record of delivery in this highly specialist area will underpin G4S’s service offering in South Africa and elsewhere in Africa,” and will assist the development of the cash business via the provision of more complete end-to-end solutions for its customers.

Ever aware of the important role of Social responsibility to its operations, G4S South Africa realises that working with people and communities, and striving to improve the places and conditions in which the whole populace works and lives, is a key part of its business across the Africa region. It is in a very fortunate position, given the extent of its footprint, and is thus able to use this important role in society to make a difference, helping people to operate in a safe and secure environment in which they can thrive and prosper.

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Even in its everyday dealings, the company aims to address societal challenges such as poverty, education and access to proper healthcare. The efforts it makes merely in its normal course of business are also significantly supplemented by extensive Corporate Social Responsibility (CSR) programmes, with efforts largely concentrated on the youth of the African continent, who G4S South Africa truly believes to hold the key, given the right enablers and support, to secure its future.

This is a company which is unashamedly ‘Afro-optimists’ and one that genuinely believes in the opportunities afforded by the continent. Its commitment to making a sustainable, measurable difference to the lives of employees is all too apparent, not least to the Top Employers Institute, and G4S is determined to continue to apply this dedication to the clients and communities it serves, to further the progress it has already so successfully achieved.

.

“Our comprehensive research concluded that G4S provides an outstanding employment environment and nurtures and develops talent throughout all levels of the organisation”

G4S South Africa

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Bringing nature back down to earth Editorial: Christian Jordan Production: Janis Billington

SME Lightning Protection and Earthing is one of the country’s industry leaders when it comes to protecting physical structures and expensive equipment from the devastating power of a lightning strike. Businesses without protection can lose time, money and people as a result of a lightning strike so the question is, are you willing to take the risk?

Have you ever considered what the result would be if a lightning bolt was to strike your office or the ground around your building? It’s safe to say the consequences would be detrimental to your business and potentially fatal to your employees.

A glance at a science text book will tell you that a lightning strike is essentially a large scale electrical discharge between clouds high up in the atmosphere and objects on the ground.

However, there is still a lot that is unknown about lightning strikes but we do know that the ‘bolts’ can often be just one inch in diameter even though they appear much larger to the eye thanks to their power.

The most common form of lightning strike in South Africa is an indirect strike, meaning instead of striking a building or mast (direct strike), the bolt will hit the ground or an external object such as a tree or building and find the easiest path down to earth

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via buried cables or water pipes. This sort of strike can be very disruptive for businesses, potentially putting a stop to activity for weeks but if you are prepared you can avoid this commotion and all of the financial drama that comes with it.

SME Lightning Protection and Earthing is one of South Africa’s premier operators in the lightning protection industry and with their assistance you could potentially save a lot of time, money, hassle and maybe even an employee’s life.

The company has a long list of successful projects and happy clients and is currently planning for major jobs with high-profile customers in 2014. The history of the company however, shows that the focus was not always on lightning protection. In fact, in its early days, SME was all about supplying equipment to miners as Managing Members, Julie Kohler and Marius Janse Van Rensburg explain.

“The name SME comes from Steam and Mining Equipment which was a Johannesburg based company owned by a Jewish

SME Lightning Protection and Earthing

Lightning storm over Cape Town city center

doctor,” Julie says.

“Our predecessors, whom Marius and I purchased the shares from, were mainly supplying equipment to the mining industry and eventually they began supplying lightning protection installations to the mines. They then opened in KZN and started SME Lightning Protection as a result of the lightning protection work that was done in the mines in Gauteng. So, it all stemmed from the mines and in South Africa mining forms a large percentage of our GDP.” While the company now operates in many industries, servicing companies from a range of backgrounds, their success stems originally from the mining industry and Julie explains that a recent resurgence in mining activities has seen SME finding more recent opportunities with mining companies.

HEALTH AND SAFETY A lightning bolt can contain millions of volts of electricity and,

of course, when dealing with such a powerful natural force, you need to have hefty industrial equipment and well thought out designs to ensure that the strikes are dealt with safely. When installing equipment of this nature, health and safety has to be the first consideration, just as it should be on any industrial construction site. But safety is not just a concern during the installation, every year lightning protection equipment has to be serviced to ensure that nothing has been compromised through use.

“Safety is becoming crucial in all aspects of a construction project and lightning protection and earthing is a big part of that,” says Marius.

“Any mine that is using explosives needs auditing every 12 months as per the code of practice. This is why our expertise is becoming more of a necessity. In the past, lightning protection was a luxury, now it is a requirement to comply with codes of practice.”

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SME Lightning Protection and Earthing Even the government is weighing in to ensure that health and safety standards are not violated.

“The Department of Labour is visiting all construction sites and they are shutting down sites that don’t comply. There is a big drive towards health and safety in the industry and the country as a whole,” Julie says.

Fortunately, SME is committed to its mission statement “to strive for perfection in everything we do” and that encompasses health and safety targets set out the company and adhered to by everyone.

“A lot of our work stems from having ISO certification.

We are still the only lightning protection company with ISO certification in South Africa. It does secure a lot of work for us as companies insist on compliance to international codes and standards,” explains Julie.

COMPETITIVE ENVIRONMENT ISO certification is just one of the ways in which SME separates itself from the competition. In addition to this there is obviously the many years of experience, the vast amount of technical expertise and the extensive list of products and services that the company offers. Because of this, some of the country’s biggest businesses call SME their partner.

“We work a lot in the mining industry but we also work extensively in the sugar industry, in the power industry on Eskom sites, we work on solar farms, at water purification plants, pump stations, and also a lot with Multi Choice, Vodacom and MTN on their installations,” explains Marius.

“There are three big players in our industry in South Africa of which we are one. Over the years people who work for these companies will break away and start their own business which consists of one bakkie and a crew. They will work on all the small projects whereas we focus on the bigger projects as we can sustain these financially and we have proven technical expertise which sometimes the smaller companies do not have,” he says.

“We deliver a complete product. For example, we start with the technical design and drawings, from there the installation takes place and we then close out with SABS certification. A lot of the smaller companies can only do the installation and cannot do design and AutoCAD drawings or maybe they can do everything but they don’t have certification which is a problem for the client. From start to finish, the delivery of a complete service is one our biggest selling points. The client gets a one stop shop; consultancy, design and installation, they come for the complete product,” Julie says.

SME’s list of services goes way beyond just design, installation and maintenance. The company offers services to the general construction and electrical industry, making full use of its skills portfolio and maximising the potential of investments that have been made into equipment.

“The nature of our business sees us installing electrodes into the ground and these can be anywhere from 1.8-30 meters deep,” says Marius. “Wherever we go we are finding challenges with underground services so we invested in an underground services scanner to determine where all the services are. We then took this one step further and offered the service to other companies, outside our core scope of work.

“We also do a lot of drilling and excavation where we are working on substations. We can sometimes do up to 4000 meters of trenching per site so we purchased an excavation machine to help us complete projects quicker. This quick turnaround time is invaluable to the client.”

LIGHTNING SEASON The amount of lightning strikes and the strength of these strikes is amongst the highest in the world in South Africa. A large proportion of these strikes occur between September and March – lightning season – a time when the number of insurance claims rise and when the number of enquiries for SME’s services increase.

“We used to be less busy in July, August and September because there was no lighting during these times but since the focus on health and safety has increased, we are now constantly busy. In September, October and November we get more enquiries as there is more lightning related damage,” explains Marius.

“In South Africa, indirect lightning strikes are the most common. The current will dissipate through the earth and enter the building through cables, water pipes or any conductor present,” he says.

“This will lead to IT equipment being damaged, electrical surges which can cause extensive damage and this affects both the domestic market and the industrial market,” adds Julie.

“In South Africa, indirect lightning strikes are the most common. The current will dissipate through the ground and enter the building through cables or water pipes” Insurance claims as a result of lightning damage have risen to around R6 billion per year, mainly because of the expensive equipment that is damaged in a strike but Marius suggests that the company works closely with the insurance companies to

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SME employee at the Moses Mabhida Stadium during construction ensure the correct coverage is supplied.

“Whenever there is a lightning related claim the relevant insurance companies contact us so that we can go out to the sites, assess the damage and submit a proposal,” he says. “Our certificate is accepted by most of the insurers so if there is another claim the client will be covered.”

CHALLENGES Although business is good for SME, with multiple contracts on the horizon and successfully completed projects on the record, the company invariably faces challenges. While the first challenge you may think of might be winning new contracts or the price of equipment, it is in fact a longer standing issue that fuels challenges for the company and that issue is people.

First of all, there is the challenge of finding the correct people and getting them up to the required skill level and secondly, there is the challenge of BEE legislation.

“Training is a challenge for us,” says Julie. “Mostly, you cannot just find the perfect field installers - basic literacy and maths skills are quite poor so we invest in every employee and try and make their situation the best it can be, financially and in terms of lifestyle, so that they are not constantly solicited by our competition. When I say competition, it’s not just lightning protection people.

“When we are working on a construction site, some of our

PAGE 88 DEC 13

The completed stadium good workers get noticed and other firms will make offers so it’s quite challenging to get their skills up to the appropriate level and then everyone else wants them so retaining staff is very hard.

“One of the big challenges that most South African companies face, and one that is particularly challenging for SME, is BEE legislation. The legislation requires that all government tenders, regardless of price and service delivery, have three quotes and the company with the highest BEE scorecard tends to get that work. To get your scorecard to the highest level, Level one, you need to have black ownership.

“We are finding that more and more of our work is coming from the private sector rather than government because we don’t have that black ownership. It is something that we have looked at it in the past but obviously there can’t be fronting; it has to be absolutely legitimate ownership.

“A lot of the government work is awarded to companies with black ownership who don’t necessarily have the degree of skill that the three big players have. This is a big challenge for us and is prompting the rise of competition that was not there before,” explains Julie.

Away from the people and BEE challenges, there is another more tangible problem that is always a cause for concern, not just for SME but the entire construction industry.

“Copper is one of the products that is used in many of our

SME Lightning Protection and Earthing installations because of its properties. It holds huge value with scrap dealers so after an installation, people will come and rip it up and sell it for scrap and the cost of replacing it is huge. This is a major challenge in South Africa. There is a product that has been developed to prevent this theft but again, it is expensive,” says Julie.

“That product is called Kwena cable,” explains Marius. “The strands are woven in such a way it makes it impossible to take the copper from the other metal and it’s useless as scrap so dealers will not take it. It is beneficial but it can be up to four times the price of a regular cable and sometimes people will steal it anyway.”

AFRICAN EXPANSION Since its inception nearly 30 years ago, SME has grown exceptionally and because of its unique, first-class service offering, the enquiries keep coming in and not just from South African companies. SME has worked all over southern Africa and is looking to do so on a larger scale in the future.

This growth has been in line with some of its longstanding customers who are also growing into Africa.

“We operate in all corners of South Africa. We are also operate in our neighbouring countries, Swaziland, Mozambique, Botswana, Madagascar, Zambia, Tanzania, Namibia, Ghana and Kenya. There are huge opportunities in other African nations,” says Marius.

“Those opportunities are being driven by one particular company which does TV satellite services and cell phone services and they are expanding throughout Africa and they have partnered with SME along with Ilovo Sugar. These two partnerships enable us to spread throughout Africa,” Julie explains.

“We are aware that service is vital. If our service is poor we are not going to maintain these relationships,” states Marius.

Examples of SME’s work and fantastic service offering can be seen in flagship construction projects around the country.

Two of the most notable projects include the Moses Mabhida stadium and the King Shaka International Airport.

“The World Cup coming to South Africa was a huge deal for us with soccer being the number one sport in the country and our work on the Moses Mabhida stadium was a significant contract for SME. This is a very high profile building in KZN and sits right on the beach front,” says Julie.

“The King Shaka airport was a quite high profile installation and again this was a government deal, outsourced to contractors,” she adds.

“At the airport, SME has done the design and installation for each and every building there; substations, terminal buildings to name a few. This is not always the case for a project of this size,” says Marius.

Of course, lightning is not a one off occurrence. Within one

year of the initial installation, SME is kept busy at these sites with maintenance, ensuring safety standards are met.

“All of the earth points are numbered and we have to do annual maintenance tests on each point. If there are damages or new buildings or roads put down, everything has to be taken into account when we do the maintenance,” he says.

However, even though these projects are flagship in terms of their popularity, it is the on-going contracts with longstanding customers that generate real value for SME, as Julie explains.

THE FUTURE As the company grows into 2014, it is certain to see a growth in the workforce, a growth in the amount of work and a growth in the amount of satisfied customers.

Marius explains more about two notable projects in the pipeline saying: “We are busy with two major projects; one is Musab Uranium in Namibia where we are currently submitting all of the final designs for the substations and the mine. The other is a solar farm in the Northern Cape where the client approached us for the design and current injection tests.”

As long as lightning continues to threaten safety and operational ability, businesses will always need to be prepared for lightning eventualities and insurance claims aside, if you don’t have protection you are running a big risk.

Marius concludes by telling us that SME can offer everything a business would require when it comes to lightning protection and earthing saying: “We have the expertise, technically and commercially, and we always deliver on time.”

.

“We invest in every employee and try and make their situation the best it can be, financially and in terms of lifestyle, so that they are not constantly solicited by our competition” Phone: +27 31 701 7582 Email:sales@sme.co.za

www.sme.co.za

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Acquiring a brighter future Editorial: Lauren Grey Production: Chris Bolderstone

Since its inception, Bearing Man Group has been involved with many acquisitions, partnerships and distribution deals in order to expand its product range and develop its services.

IndustrySA featured the South African engineering giant in 2012, and in just one year, the company has more exciting news to announce…

As one of South Africa’s leading engineering companies, Bearing Man Group (BMG) does more than supply industry with a vast range of superior quality engineering components; it also provides the technical resources needed to keep machinery operating at an optimal level.

Established in 1974, the company started by selling bearings, but has since expanded its product range rapidly to include a range of the finest globally recognised brands in the world. Subsequent to its success, BMG has expanded from its single office in Durban, into Africa; with branches opening in Namibia, Swaziland, Zambia, Botswana and Mozambique.

CEO, Charles Walters says that the company’s continuing success is largely a result of ‘strategic acquisitive growth’, which has enabled it to reach new markets and expand its service offerings over the years.

In spring 2012, IndustrySA featured BMG after it announced two high-profile acquisitions, with the purchase of

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Gasket and Allied Products and its largest acquisition to date, Man-Dirk (Pty) Ltd. These strategic investments increased the company’s high-quality product range and invaluable industry knowledge tremendously, further reinforcing its position as one of South Africa’s leading engineering companies.

Since then, the company has gone on to secure even more acquisitions, partnerships and distribution deals, as part of its development and growth strategy.

BMG’s most recent partnership has extended the BMG range of pneumatic and hydraulic filtration products and systems, whilst enabling it to reach new markets throughout sub-Saharan Africa.

PARKER HANNIFIN PARTNERSHIP The partnership is with international engineering company, Parker Hannifin, a global leader in motion and control technologies, with a presence in 49 countries around

Bearing Man Group

©BMG the world.

Parker Hannifin has been operating for 41 years in South Africa, providing quality services and products to its SubSaharan African customers and to other companies through its strong, professional distribution network, distributor owned ParkerStores and Parker owned ParkerStores.

The company’s portfolio of precision-engineered solutions for the mobile, industrial and aerospace markets will now be accessible to BMG through its recent partnership, as Charly Saulnier, President Europe, the Middle East and Africa for Parker Hannifin, explained in a statement.

“At Parker, we make a conscious effort to find ways to deliver our products, more efficiently to a growing footprint,” he said.

“Our strategic partnership with BMG will enable us to reach new markets, while giving BMG fast access to our extensive portfolio of products and technologies, from a single source.

“For our customers in South Africa this means the quality products of the world leader in motion and control will be available locally with excellent customer service provided by BMG through their extensive network.”

Similarly, Gavin Pelser, BMG Executive Director says that the partnership will enable both companies to reach new markets “throughout Sub-Saharan Africa, particularly in mining, manufacturing, process, transport, construction and logistics.”

TIMKEN DISTRIBUTOR In order to expand its footprint within the bearing market, BMG have secured a distribution deal with Timken, a global steel and bearing manufacturer with operations in 30 countries.

The deal will see BMG distribute Timken’s range of bearings, including standard anti-friction bearing configurations and advanced products, like housed units, integrated bearing assemblies, precision assemblies and

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©BMG

aerospace bearings.

Rouff Essop, general manager of BMG’s bearings division said in a statement, that Timken use the “highest quality materials” in the manufacture of its products, “BMG’s portfolio of Timken housed units are designed for reliable sealing, ensuring enhanced bearing protection in harsh operating conditions, including debris-filled, contaminated or high moisture environments, the robust housed series includes pillow, plummer and solid block housing units.

“Timken use the highest quality materials in the manufacture of these units, to meet the stringent requirements for cleanliness, machinability and performance required in demanding operating conditions.”

BMG AUTOMOTIVE In a bid to enhance its automotive division, BMG recently began distributing BEST tyre protection sealant and was appointed exclusive distributors in Africa of Rexon automotive belts.

BEST tyre protection sealant is a new international brand, manufactured using thixotropic and colloidal resin, containing micro fibres and recycled rubber crumb materials, with cooling agents and rust inhibitors that protect all metal parts.

In a statement, general manager of BMG Automotive, John Black says that BEST is “reliable” and “cost effective”, “BEST, which is non-toxic and water soluble, is injected into the tyre

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through the valve, without the need to dismantle the wheel from the machine or the tyre from the rim.

“In the event of a puncture, this sealant automatically creates patches and plugs, sealing holes caused by foreign objects. This material also eliminates leakage from hidden rubber pores and seals valve leakages and prevents air pressure leakage from the rim and o-ring.

“This sealant efficiently seals around objects embedded in the tyre up to 50 mm, prohibits internal rubber separation and also reduces overheating of the rubber mass and the metal armour of the casing.”

The sealant is break-down, boil and freeze resistant (up to -25°C), and improves safety for the driver, reduces fuel consumption, lowers maintenance costs and minimises rim assembly problems.

Furthermore, as Africa’s exclusive distributor of Rexon automotive belts, BMG now stocks a new range encompassing the classic fan belt or V belt, as well as the ribbed PK range, also known as a serpentine or multi rib belt.

The belts have been designed to withstand increasing underbonnet temperatures, caused by smaller engines, Black says, “Over time the design of engine bays in modern vehicles has become smaller, yet engine outputs have significantly increased, leading to higher under bonnet temperatures.”

The new range uses higher quality materials with greater heat resistance, manufactured in a world class facility, with

Bearing Man Group

computer controlled processes, to stringent quality standards, including ISO9001 specifications.

BMG FUTURE Through its many strategic acquisitions, partnerships and distribution deals, BMG is continuously working towards its vision of becoming a powerful force within the engineering industry by providing superior technical solutions to its customers.

The company intends to further add to its portfolio of leading brands, quality products and technical skills in order to service the engineering industry thoroughly.

Its strategic vision going forward however, is to aggressively expand into Africa, which the company intends to achieve within the next five years.

African sales currently constitute a substantial percentage of BMG’s turnover, and the company intends to focus its efforts on Ghana, Nigeria, Angola, Tanzania and the DRC.

.

©BMG

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Danfoss (Pty) Ltd P.O. Box 5022, 2128 Rivonia, Sandton, South Africa Tel. +27 11 785 7600, Fax. +27 11 803 8244

OCT 13 PAGE 93

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Protecting your company’s greatest asset Editorial: Lauren Grey Production: Leslie Kemp Following on from the success of its high-quality range of catering uniforms, South African manufacturer of protective work-wear, Gross & Co is now looking to expand its market share within the mining industry. IndustrySA finds out more about the highly anticipated new clothing range.

More than just a piece of branded fabric, uniforms form an integral part of work culture across the globe; they are used to distinguish staff from customers, add a sense of belonging and create equality in the workplace.

It is understandable therefore, that choosing the correct uniform is not only important, but essential, because it is often considered an extension of a company’s brand, and a way to unite its employees.

With this in mind, there are also other factors that need to be considered when choosing the correct uniform; it needs to be hard-wearing, comfortable, easy to clean and protective for those working in the catering or hospitality industries, for example.

Although this may seem like a daunting task for some,

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luckily there are companies that specialise in corporate uniforms, who understand the functions that a uniform needs to fulfil, and who do most of the hard work for you.

Johannesburg-based Gross & Co is a clothing and textiles manufacturer specialising in protective work-wear for the catering industry. The company’s brand, Chef Works, is globally renowned and has roots dating back more than four decades within South Africa.

Established in 1964 by Joseph Gross, the company began by addressing the market’s ever-increasing dependency on safety in the workplace with quality and image at the forefront.

Today, with the help of his five sons situated on four continents, the company has clients across the globe, distributing to over 30 countries and listening to each

Gross & Co

individual requirement.

The company’s “overall protection” promise also covers its range of protective garments for the industrial industries, hospitality industry and corporate clothing, as well as manufacturing medical scrubs.

INDUSTRY INNOVATION Gross & Co prides itself on recent innovations within the protective clothing industry, which has made work-wear for chefs more durable and comfortable to move about in.

Previously, uniforms had been basic and made of uncomfortable fabrics designed only to protect the chef from hazards such as hot oil spills.

However, understanding the needs of its customers who wanted a more comfortable and fashionable uniform,

Gross & Co designed a range using cotton and polycotton fabrics, with a cool-vent design, known as Chef Works.

The Chef Works range provides aprons, hats, jackets and trousers, designed for chefs, kitchen staff and front of house staff within the catering business.

The company’s innovative uniform range provides great value for money and can be customised with instock items or made completely from scratch.

On top of manufacturing protective clothing, Gross & Co also has a luxury laundry service that it offers clients. The company charges per wash and the service is particularly popular in the food service industry, where employees require clean uniforms on a daily basis.

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Gross & Co NEW MARKETS Subsequent to the success of Chef Works, Gross & Co now hopes to penetrate the South African mining industry, by providing a unique range of protective work-wear in new, high-quality, stylish options.

The company has been working on its mining range for the past three years, ensuring that each product is designed specifically for the needs of the industry. One of the products already available for order is a boiler suit, with knee and elbow pads sewn in.

Typically, uniforms for the mining industry have a short lifespan due to the working environment, however Gross & Co have specifically designed this high-quality, durable product to be both safe and long-lasting.

Aside from protecting clothing, the company also manufactures safety equipment, such as safety glasses, face shields and respirator masks to accompany the uniforms.

FUTURE EXPANSION Since launching the business in Johannesburg, with little to no national presence in the first few years of business, Gross & Co has grown into a worldwide organisation

but still manufacturers locally.

The business not has 15 sales reps and 12 agents across South Africa, with 75 distributors in the country, as well as in Zambia, Namibia, Tanzania, the DRC, Zimbabwe, Mozambique and Angola.

Going forward, the company’s mission is to increase exposure of the brand and visibility of the product, which it hopes to do via its newly established franchise stores opening across the country.

The company has two franchises stores in regional shopping centres at present, and are preparing to launch its third very soon.

.

“Gross & Co prides itself on recent innovations within the protective clothing industry, which has made work-wear for chefs more durable and comfortable to move about in”

OCT 13 PAGE 97

INDUSTRY RECOMMENDED

This is the latest installment of our Industry Recommended directory, a list of companies across a range of industry sectors over SA.

AGRICULTURE HIGHVELD HONEY FARM Wholesale and retail honey suppliers +27 11 849 1990 LONA CITRUS Cape Town based Lona Citrus has been exporting quality South African citrus for the past 17 years +27 21 481 8200 www.lona.co.za AUTOMOTIVE BEEKMAN SUPER CANOPIES One of three major canopy manufacturers in South Africa, renowned for its superior product quality and excellent customer service +27 21 948 3701 www.beekman.co.za

PROTEA POLYMERS A leading importer, stockist and distributor of plastic raw materials and additives for the polymer industry in South Africa +27 11 799 6299 www.proteachemicals.co.za CONCRETE SCRIBANTE CONCRETE Suppliers of ready-mix concrete, plaster, topping and mortar 27 41 406 9500 www.scribanteconcrete.co.za CONSTRUCTION BAY WEST MALL Port Elizabeth’s biggest Mall, under construction and set to open in 2015 www.baywestmall.co.za

MAXE STAINLESS STEEL Maxe Stainless Steel has a significant market share in the South African Automotive Accessory market +27 31 713 2200 www.maxe.co.za

ENGINEERING BMG One of South Africa’s leading engineering companies, focussed on supply the industry with a vast range of superior quality engineering components +27 31 576 6200 www.bmgworld.net

CHEMICALS ENTEK INDUSTRIAL CHEMICALS Offers product development to all industrial products with laboratory back up +27 31 766 3325 www.entekchemicals.com

FANCRAFT Maintenance, problem solving, repairs, overhauls and reconditioning of turbines, compressors, pumps, gearboxes, fans & other rotating equipment +27 16 986 0795 www.fancraft.co.za

PAGE 98 FEB 98 SEP 13 13

FINANCIAL SERVICES FINANCE SPEC Offers a wide range of accounting, auditing & consulting services to assist you and/or your organisation with its business & financial needs +27 31 765 6553 www.financespec.co.za FOOD SUNSPRAY South Africa’s largest producer of spray-dried food products has been operating within the local market for more than 50 years +27 11 473 6800 www.sunspray.co.za LIGHTNING PROTECTION SME LIGHTNING Specialists in lightning protection and earthing +27 31 701 7582 www.sme.co.za LOGISTICS HAMBURG SUD Globally operating transport logistics organisation www.hamburgsud.com JJ LOGISTICS A diverse and uniquely structured transport company based in KZN +27 36 633 0121

INDUSTRY RECOMMENDED

M&M TRANSPORT Experts in the transport of citrus, other fresh produce, packaging material, animal feeds, fertilizers and construction materials +27 15 293 2789 TIME FREIGHT One of South Africa’s leading road express businesses providing a comprehensive road network for rapid collections and delivery throughout the country +27 33 341 6100 www.timefreight.co.za METAL HOWICK METAL PRODUCTS Fully integrated brass window and door hardware manufacturer and distributor +27 33 330 3534 www.howickmetal.co.za MINING IMERYS SOUTH AFRICA A multinational company which specialises in the production and processing of industrial minerals www.imerys.com WASTE LEGENDS A total waste management company dealing in different waste streams including hazardous waste 013 235 3047 DANFOSS Leading manufacturer of electronic, mechanical and intelligent “mechatronic” devices +27 11 785 7600 www.danfoss.com PACKAGING TUFBAG Industry leader in flexible intermediate bulk containers +27 32 459 5050 CHIORINO Market leader in conveyor and process belts, flat transmission belts and rubber aprons +27 31 792 5500 www.chiorino.com

PIPE SYSTEMS MARLEY PIPE SYSTEMS Manufacturer of plastic pipes and fittings +27 11 739 8600 www.marleypipesystems.co.za SUN ACE The World’s leading producers of PVC additives and metallic stearates +27 11 552 6200 www.sunace.co.za SICA Globally renowned Italian producer of downstream equipment for plastic pipes +39 0544 88 704 www.sica-italy.com REFRIGERATION ETHEKWINI COLD STORES Premium cold store in Durban +27 31 913 1800 www.ethekwinics.co.za RENEWABLES DCD WIND TOWERS The newly-established Wind Towers subsidiary of international manufacturing and engineering company, DCD www.dcd.co.za +27 16 428 0133 HAILO WIND POWER Hailo is the only supplier of quality tower equipment of its class that installs all over the world and is present in all key markets providing support for its customers +49 2773 82 0 www.hailo-windsystems.com SECURITY G4S The world’s leading international security solutions group www.g4s.co.za SOFTWARE SAGE VIP PAYROLL Providers of a total payroll and HR solution including system implementation, training and call centre support +27 12 420 7000 www.vippayroll.co.za

TEXTILES GROSS & CO. Industrial protective work wear and corporate clothing manufacturer +27 11 624 3300 www.gross.co.za M&P TRIKAM Wholesale textile & trimming merchants distributing nationwide to the clothing industry. +27 11 836 5716 www.mptrikam.co.za TRANSPORT MKONZA TRANSPORT Providing quality, safe and innovative tourism and transportation solutions +27 11 315 3336 VENTILATION CURVENT INTERNATIONAL Ventilation and fire ventilation specialists able to design, manufacture and install a wide range of ventilation systems www.curvent.co.za +27 11 826 5959

For more information about how your company can be recognised for excellence across many areas please get in touch.

Your Industry, Their Future, Our South Africa SEP 13 PAGE 99

© Michael Poliza

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