COMPANY PROFILE
2013
GRW
Driving manufacturing in SA
company report
GRW:
Driving manufacturing in SA Editorial: Roland Douglas Production: Chris Bolderstone
GRW Finance Executive, Niel du Plessis, tells IndustrySA that the company has big plans for the future including expansion into Africa, new facilities in South Africa and exciting advances in welding technology. We find out more about the industry leading business, based in Worcester, Western Cape.
Every now and then, we come across a company that is driving an industry with innovative and quality concepts and this month we found a great example of this in the form of GRW, a Worcester based company excelling in the business of trailer and tanker manufacture. GRW has the mission of building world-class road tankers and trailers conforming to the highest international quality standards. The history of the company dates back to 1989 when Gerrie van der Merwe, a former mathematics lecturer, made the move to join his brother-in-law’s road-tanker transport business. Soon after joining the business, Gerrie obtained full control and was joined at the helm by sons Gerhard and Wentzel along with long-time family friend and
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associate Rossouw van Eeden. The three young business men immediately went about having an impact on the industry and after finding existing manufacturers products to be inferior in many ways, the trio opted to build their own tankers. After many months of effort in research, design and manufacture, a prototype was built that met all standards and expectations and, in 1996, GRW was formed. In the early days of operation, GRW built tankers for the wine industry and through innovation, teamwork, strong relationships and a highly skilled and committed workforce, the company has gone on to become the industry leader in its market. By always exceeding customer expectations, GRW is quickly becoming known as one of the best tanker manufacturers around. Niel du Plessis, GRW Finance Executive, says that
GRW
while growth since 1996 has been great, the company is still looking to expand its footprint with new facilities and, potentially, operations in other African nations. “We have a new service centre opening in July in Johannesburg. This will be for the service, refurbishment and repair of trailers and tankers. We will focus primarily on GRW related products but we can also work on other brands. “The area is perfect as it is home to the biggest concentration of our clients in South Africa and it is also a springboard into Africa. The previous facility in Johannesburg near Soweto is not ideally situated to serve the African market whereas our new facility is in a much better location and is much closer to the truck dealerships which are obviously linked to our business. “When we open the new facility, the old facility in
Johannesburg will close. “We are definitely looking to expand into Africa, specifically Zambia, Tanzania and our direct neighbours Namibia, Botswana, Zimbabwe and Mozambique and we are also seeing potential from Ghana so that is where will focus for now. “You have to make sure your activities suit the region, I don’t think we will be moving any factories into any of these countries but we will definitely consider regional requirements. Overall the core activities will remain the same.” CEO, Gerhard van der Merwe, reiterated this point telling Tanker Talk magazine: “Considering the uncertainty of the local market, we will direct attention to markets north of the border. The sub-Saharan authorities are increasingly targeting the payload factor and
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company report
legitimate businesses are looking for more innovative and compliant transport solutions. “A greater number of South African companies are also looking north for future growth. We intend to take all these factors into account to increase our market share in the future.” One of the significant contracts that GRW has been involved with, building the brand and showcasing its focus on quality, came back in 2008 when GRW was approached by the UK division of global logistics firm Hoyer, to build 80 aluminium fuel tankers. These fuel tankers were used by Shell, to deliver their products throughout the UK. GRW’s wholly owned subsidiary in the UK provided after sales service and maintenance but the tankers were manufactured at the company’s headquarters in Worcester. Van der Merwe told Engineering News that the deal was a real coup for South African engineering. “Given the stringent quality criteria applied by fuel companies for road tankers, the contract should be considered as a major feather in the cap for South African engineering,” he said. “As a South African company, we were able to not only match, but also better the standards of our overseas competitors.”
ULTRA-MODERN GRW has built its name on a quality product and to achieve this, the company utilises what it calls ‘two
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ultra-modern’ production plants. This has ensured GRW tankers are renowned for their resistance to fatigue and their dependability in the harsh conditions of SubSaharan Africa. The facilities total around 20,000m² and are packed out with the finest in high-tech equipment. The facilities are constantly being updated and reviewed and GRW are always experimenting with new technology to ensure they remain on point with all new innovative ideas. One of the most recent focusses has been on welding, particularly friction stir welding and robotic welding. Friction stir welding is a form of joining that has become popular in the last 20 years but is not yet widely used in tanker manufacture in South Africa. The technique involves running a rotating cylindrical shaft with a profiled nib along the joint between two clamped sheets. Frictional heat is generated and causes the metal to soften, without melting, into a forged consolidation of the weld. “We recently did some work with the Nelson Mandela Metropolitan University in Port Elizabeth where we are testing and working with friction stir welding technology. “We are constantly expanding and investing in new equipment, we are at the forefront of the manufacturing process. “We are also focussing on increasing the robotic welding in our processes in order to increase the ...continues on page 7
Since its humble beginnings in small rented premises in Wadeville, B.E.D. has grown into a major national distributor, operating across Gauteng North West Province Free State Platinum Province Western Cape Limpopo and Mpumalanga.
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The Bolt & Engineering Distributors Group (B.E.D.) has been supplying the construction, mining and agricultural industry with quality tools and fasteners since 1983.
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GRW
...continued from page 4 reliability of our products, eliminating human error from welding,” says du Plessis. How does the company produce products of such a high quality so consistently? One of the important quality measures that have been put into place is the use of external verification bodies to confirm that all standards are reached. “We also use third-party authorised inspection authorities to sign-off on all our builds,” says du Plessis. When it comes to improving processes, the company is always looking to work to the highest European standards and take influence from the best in the industry. “Visits in early 2012 to trailer manufacturing operations in Europe gave us an opportunity to examine the efficiencies in our business,” van der Merwe told Tanker Talk. “We compared technologies both in process and product. Technically, we are very close to the European market, but in processes we have to become more efficient in order to be more cost effective.” In 2008, GRW received a Gold award from the South African Institute of Welding (SAIW), the highest award the institute offers, in recognition of continuous development and application of modern welding and cutting technology. This is just one of a selection of awards that GRW has picked up over the past few years, further highlighting the company’s commitment to excellence. The company’s philosophy surrounds the issue of
quality and, throughout the entire process, there is a strict adherence to the ISO 9001:2008 quality management system and the ISO 3834 (Part 2) system that assures quality in welding. As with the gold award from SAIW, GRW is in exclusive territory with the ISO 3834 system, being only the ninth company in South Africa to achieve the recognition.
QUALITY PEOPLE Even with ultra-modern facilities you still need a highlyskilled and highly-talented work force and the people at GRW are afforded every opportunity to ensure that their skill-set is as advanced as it can be. “This company is built around its people, quality people,” van der Merwe explains in the company’s corporate video. “We will continue to invest in our people. We are well set for growth opportunities. We are looking to expand our product range and our global footprint.” The company makes use of South African institutions ...continues on page 10
“We have a new service centre opening in July in Johannesburg”
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CORPORATION DISTRIBUTORS OF
MEASUREMENTS SOLUTIONS PRODUCTS
The Energy Business of JBT South Africa is a specialized business that is concentrated in custody transfer measurement systems. JBT South Africa’s partnership with FMC Measurement Solutions and FMC Loading Systems in Southern Africa has resulted in an unequalled solutions orientated provider to the oil industry in the region. As a world leader in flow measurement and control of petroleum products since 1933, today's FMC Measurement Solutions delivers technical superiority with a complete range of liquid and gas custody transfer solutions. By combining the strengths, capabilities, and experience acquired over many years with a diverse product offering, JBT in South Africa is able to provide a broad range of solutions complemented by application engineering, installation, commissioning and after-sales support in all segments of the petroleum industry that we serve. Through it extensive product lines, including its highly esteemed Smith Meter® and Sening® heritage brands, FMC Technologies sets the standard for petroleum supply chain management. FMC Technologies accurate and reliable measurement solutions make the daily routine of petroleum product transportation and delivery faster, safer and more economical. Proper systems design is essential for accurate loading and unloading of straight and blended refined products at the Terminal.
SEALED PARCEL DELIVERY (SPD) - MULTISEAL
Sealed Parcel Delivery (SPD) allows a tank truck compartment to be loaded with an accurately measured volume (the parcel) that can subsequently be unloaded at a delivery site, without need for secondary measurement. * The MultiSeal process begins when a compartment is sealed after loading a tank truck * The seal remains unbroken until delivery is made to the customer, at which point the compartment is completely emptied * MultiSeal ensures that the quantity originally loaded at the terminal matches exactly with that delivered to the customer * The unbroken seal and the status-report-generated loading data {e.g. the load receipt or terminal bill of lading (B.O.L.)} confirm proof of the quantity * Sensor status changes at manlids, foot valves, API couplings and wet-leg detectors are recorded during loading, transport and discharge * The status events are stored in the on board processor for immediate or later use * Display and/or printer visualizes correct loading, discharge and sealing procedure to supervisors and receivers (service station manager)
ELECTRONIC METERING DEVICE - MULTIFLOW
The MultiFlow has been developed according to the latest state of technology, incorporating many years of experience in the application of electronic metering. Due to standardisation of electronic metering devices within the European Union development is taking place strictly to the latest regulations for the approval of meters for W & M regulated applications within the EU (OIML R117). This guarantees that the MultiFlow will fulfil the present and also future legal requirements for meters for applications subject to Weights & Measures inspection.
LEVEL GAUGING SYTEM - MULTILEVEL ®
The Sening level gauging system MultiLevel provides accurate volumetric measurement of liquid petroleum products from tank trucks without restricting the discharge flow rate. The MultiLevel system increases flexibility in transporting petroleum products making distribution more cost effective. Benefits Dry line discharge measurement system Low system weight increases the payload High discharge rate Simultaneous volumetrically measured discharge from several compartments Simple to operate Cost-effective calibration process Convenient level sensor installation into compartment bottom System extension with Sening® EMIS communication interface (GPS, GPRS, Printer) System enhancement with NoMix cross-over prevention technology
CROSS-OVER PREVENTION - NOMIX
When loading a tank truck or discharging fuel at the service station, the driver has the responsibility to make the correct hose connections. As simple as this everyday routine may be, mistakes still occur. Filling tank trucks or service station storage tanks with the wrong fuel can cost distributors large amounts of money in: Downtime of tank trucks and/or service stations Tank cleaning Treatment and/or disposal of the mixed product back at the refinery Tarnished brand image for the supply and oil companies Damage to vehicles ®
The Sening NoMix cross-over prevention system prohibits products from being loaded or dispensed in the wrong compartments. Simultaneously, NoMix provides maintenance of all quality and safety requirements for loading and unloading petroleum products. Benefits
Prevents cross-over during loading and unloading Discharges with multiple hoses Cuts downtime at the service station Safely recovers vapors during filling and discharge “Shadows” actual work activities Can be used as a Sealed Partial Delivery (SPD) system by connecting additional components Eliminates driver error Saves time at the terminal and the service station Connects to Enterprise Resource Planning (ERP) systems
BOTTOM LOADING EQUIPMENT ®
Sening offers a complete range of proven mechanical products and systems for bottom loading applications which can be combined with state-of-the-art electronic technology. Benefits Higher flow rates Increased efficiency Vapor recovery Increased driver and operator safety Sening components are in accordance with international standards for bottom loading of light petroleum products. Manlids - 20" (according to EN 13314, 13317) - 16" (according to AS2809.2-1999)
Branches: Cape Town : (021) 982 1130 Johannesburg : (011) 422 2290
Business Manager Kevin Jamison kevin.jamison@jbtc.com
Account Manager Corne Stapelberg corne.stapelberg@jbtc.com
SUPPLIERS OF TANK TRUCK METERING, SEALED PARCEL DELIVERY SYSTEMS, TANK TRUCK FITTINGS AND TERMINAL MEASUREMENT SOLUTIONS PRODUCT INFORMATION: www.fmctechnologies.com
company report ...continued from page 7 when it comes to the development of its staff and du Plessis says that South African universities offer brilliant engineering courses. “We train in South Africa, our universities are very good when it comes to mechanical engineering but sometimes we will send people overseas. We are working a lot with Chinese companies and one of our guys was there recently to learn from their factories and processes. “We focus a lot on the quality of our work; we’ve invested in quality personnel and systems. We need to be at the forefront of quality and manufacturing especially as we are exporting to Europe so we are trying to maintain highstandards throughout all of our production. “Our requirements for engineering staff are high given the nature of our business and given that you constantly have to develop and improve designs while staying technically ahead of the competition and improving cost efficiency. From time to time, we will send our engineers on special courses to ensure they are up to date. “At GRW we believe that a high-quality product can only be built by highly skilled individuals. We invest a considerable amount of time and money in training and developing our people, which enables them to achieve the
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very high standards that are intrinsic to the GRW brand.” Engineering knowledge is of course an important element of the skill set required by the staff at GRW and du Plessis says that the management team is nearly 50% engineers and this, along with other vital elements, makes for a great mix at the top end of the hierarchy. “There are a variety of different skills in the management team. We do have a high concentration of engineers due to the nature of the business but there is a mix. There is an HR division, I represent finance and admin, and other departments have engineers in charge. Of the current management team, about half of them are engineers or are from an engineering background.” The management team is now responsible for a huge workforce and the staff level shows just how far the company has come since its inception. “Currently in our Worcester facility there are between 350 and 400 people, in the rest of the group there are another 150-200 people,” says du Plessis.
DRIVING THROUGH HARD TIMES The company has said that it is extremely happy with achieving satisfactory results at the end of June 2012 and van der Merwe told Tanker Talk that what helped GRW
GRW during the economic meltdown and tough trading conditions was the diverse product range on offer. “The diversification of our product range has enabled us to penetrate a wider market and thus demonstrate stability in these very unpredictable times,” he said. Overall, the difficult business environment that is currently gripping the commercial world has had an impact on the GRW business but in South Africa the
market is now looking more promising. “The global economic slowdown hit us quite hard; it had a direct impact on our volumes,” says du Plessis. “Capital goods, like the ones we supply, are the first things to go down when there is an economic slump. In our UK market, things are not back to normal by a long way. The South African market is more stable, it is still ok at this stage, but on the European side we are still awaiting the recovery.”
Manufacturing, Assembling and Welding
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company report The rising cost of raw materials has also impacted on GRW. The slowdown in local production, especially steel, has forced suppliers to look abroad and import stocks and this has driven costs upwards but GRW has good relationships with South African suppliers and only has to import oversized orders. “We do feel effects from the rising cost of raw materials because of imports costs but a large component of our materials are locally sourced. Primarily our biggest consumption is of aluminium and we can get most of that locally but not all widths. Certain widths we have to import as the mills in South Africa only go up to 1910 width,” says du Plessis. In a bid to become more cost effective, GRW has placed a large emphasis on energy efficiency and waste
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management and in recent times the company has managed to refine its waste management programme resulting in only 14% of waste ending up in landfills, almost 15% being reused and more than 66% being recycled. In regards to energy usage, the company is aware of the positive effects that sound energy management practices can have on costs. The company now has a focussed resource conservation program made up of a water recycling system, the reduction of gas usage and two energy efficiency audits to reduce electricity usage and du Plessis states that as well as being eco-friendly, this helps with costing issues. “We are always looking to improve but it’s also part of a cost drive. If a green conscious can help with cost efficiency then we will do it. Our emphasis on green
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Specialising in the manufacture of: • Tanker fittings • Sealed compartment delivery systems • Fuel and gas flow meters • Pumps • Aviation refueling systems • Hose Reels • Elaflex agents (Hoses and fittings) • Manntek agents (Dry disconnect couplings)
Contact
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021 982 5474
info@alfonshaarsa.co.za
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company report initiatives has definitely helped on a cost side,” he says.
INNOVATIVE PRODUCTS As mentioned above, GRW manufacture a wide range of quality products. Happy customers include the likes of Unitrans Fuel and Chemical, D.S. Ellis Agribulk, Cargo Carriers, Sizanani Gas, Manline, Zimbulk Tankers, Stellar Transport and Warden’s Cartage to name a few. The product range currently includes, but is not limited to, refrigerated trailers, dry van trailers, rigid body meat hangers, bulk feed tankers, dry bulk pneumatic tankers, food-grade tankers, chemical tankers and aviation refueler tankers. Dry van trailers, launched by GRW at the company’s golf day in 2012, have received particularly encouraging feedback from potential customers and Fanie Roux, GRW Executive, told Tanker Talk that increased volume and weight capacities along with improved security features were proving popular with users. “The construction of the van from high-quality imported composite panels encased in steel sheets provides the insulation required for the transportation of moisture sensitive dry goods. Rubber seals on the doors ensure a waterproof environment. “The unique shortened chassis design, successfully introduced on our refrigerated semi-trailers, allows a 10% increase in the volume of goods transported, due to our being able to increase the height of the van.
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“We are constantly expanding and investing in new equipment, we are at the forefront of the manufacturing process” “Similarly, the extent of weight carried has been increased to 34 tons, as opposed to the norm of a maximum of 32 tons in current trailers. This compares well, also, with the standard tri-axle curtain-sider trailer, carrying a 36-ton payload. “The dry van, constructed from composites, galvanised steel and aluminium extrusions, also provides a level of security which cannot be matched by the curtain-siders,” said Roux. One thing that is consistent across the entire GRW product range is quality. The company’s reputation, built up through hard work and a commitment to excellence, is something that is not going to fade and with continuous research and development and the goal of becoming the leading supplier of tankers and trailers worldwide, it looks as though all is in place for GRW to roll on and achieve this target in the not too distant future.
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We offer flame and laser cutting and bending services to a wide variety of customers, from agricultural and marine to heavy engineering and to the man on the street, everyone is welcome at Vulcan Steel.
Vulcan Steel is a proud supplier to GRW Engineering
We have a laser machine with a bed capacity that can handle a plate size of 6m x 2m E-mail: information: info@vulcansteel.co.za sales@vulcansteel.co.za debtors: debtors@vulcansteel.co.za
No.8 Longclaw Drive Montague Gardens Cape Town Western Cape South Africa Tel: +27 (021) 528-8900 Fax: 0866 22 7878
+27 23 348 6300 www.grw.co.za
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