July issue

JUL

2013 ISSUE 11

Entering the Era of Wind Power DCD Wind Towers are to open a R300 million wind tower manufacturing facility at the Coega IDZ in Port Elizabeth. Marketing Manager, Henk Schoeman, tells IndustrySA that the facility should be up and running by January 2014.

Pabi Moloi Ready to dance

Bafotech IOvercoming all challenges

Calgro M3 18 years of successful projects

Aranda Textile Mills Fashion, with Italian influence

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 Hal Hutchison John Cliff Phil Bird ADVERTISING SALES SALES DIRECTOR Andy Williams SALES MANAGER Daniel Marshall SALES EXECUTIVE Holly Graham SALES EXECUTIVE Mark Leonard STUDIO STUDIO DIRECTOR Martyn Oakley LEAD DESIGNER Dom Thorby 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. © East Coast Promotions Ltd 2013

Welcome to the eleventh issue...

As always, the last few weeks have been extremely busy.

We celebrated Youth Day, the government has built strong ties with international partners including Japan and Argentina, the country’s innovations (such as the Lodox X-Ray system) continue to be internationally celebrated and global companies continue to look to South Africa as an investment destination.

Following on from an exciting Youth Day, in this edition of IndustrySA we take a look at two young men who are providing entrepreneurial and innovative excellence - a young South African, Sizwe Nzima (pg.10), who started a business delivering medical supplies to Khayelitsha residents and Anthony Mutua (pg.12), a Kenyan who is changing the future of cell phone power.

As for industry leading companies, this month we have a whole new set of successful organisations to profile including GRW Engineering, a tanker manufacturing company that has grown into a world leader; Bliss Chemicals, the company behind MAQ washing powder; Calgro M3, residential property developers and Universal Storage, warehouse and storage specialists looking to move into the African market.

It appears that expansion into African markets is now on the radar of all the major players in South Africa after the World Bank reported that, based on compounded annual growth rates (CAGR) from 2013 through 2015, 11 of the world’s 20 fastest growing nations are now in Africa and opportunities are continually cropping up across a range of industries.

Even with these fantastic stories of business excellence, we were, like the whole country, saddened by the news that Nelson Mandela was again taken ill and of course, we all wish him well.

Please get in touch with IndustrySA if you have a story of business success or inspiration. Don’t be shy - we are on Twitter and Facebook or alternatively just send us an email.

Joe Forshaw

editor@industrysa.com

JUL 13 PAGE 3

CONTENTS

3 EDITOR’S PAGE Inspiration from the youth

6 NEWS All that’s happening in South Africa 10 EnTREPRENEUR A social entrepreneur

12 Innovation Changing cell phones forever?

14 Gadget Box High powered boys toys 16 Destination Director Unique luxury 18 Pabi Moloi Ready to dance

PAGE 4 JUL 13

62

CONTENTS

20 DCD Mining & Energy

62 Bafotech

Localisation of wind tower manufacture

The one stop scraper winch shop

28 GRW Engineering

68 Aranda Textiles Italian influenced fashion

Setting the standard in manufacturing

34 John Bean Technologies

74 Shell SA

Measurement solutions

Fuel up with V-Power

42 Calgro M3

82 Wild and Marr

Eradicating SA’s housing backlog

The sound professionals

48 Universal Storage Systems

86 Remkor Technologies

Making the most of your valuable space

Family centred steel services

54 Bliss Chemicals

92 T wintec SA

Moving up in the FMCG market

Unmatched quality

58 JMV Textiles

98 Industry Recommended

From thread to finish

This month’s showcased organisations

COMPANY REPORTS

16

JUL 13 PAGE 5

NEWS All that’s happening in South Africa

GMSA awarded R6B export contract General Motors South Africa (GMSA) and component manufacturer, Tenneco South Africa have been awarded a R6 billion contract to export catalytic converters to the United States.

The converters, manufactured at Tenneco’s clean air plant in Port Elizabeth, will be used for GMSA’s next generation V-6 engines sold in the US from 2015 to 2022.

“The decision to award this contract to South Africa is a great show of support by our parent company, as it comes ahead of a clear legislative framework by the South African government to support the strategic growth of exports,” GM Africa’s managing director, Mario Spangenberg said in a statement last week.

It is projected that the programme will boost economy in the Eastern Cape by creating employment in manufacturing, supply and support services; it is also set

PAGE 6 FEB 6 JUL 1313

to benefit the country’s mining sector as an estimated 10 tonnes of platinum group metals are required over the duration of the project.

“A key characteristic of vehicle manufacturing is that we often have to plan as far as five years in advance for the next vehicle programmes” said GMSA’s international operations vice-president for global purchasing, Johnny Saldanha.

GMSA and Tenneco have been in partnership for over 12 years to produce catalytic converters for the US market, with current export levels reaching 2.6-million converters per year.

“Tenneco and General Motors have long and proud associations in South Africa spanning many years. We are delighted to have been selected by GM for this critically important programme,” said Tenneco country manager, Gary Keen.

NEWS

Obama’s visit set to strengthen trade relations

Following a visit from US President, Barack Obama as part of his three-nation African tour, President Jacob Zuma has said he can foresee a strengthening in trade relations between the two countries.

Addressing guests during a dinner held in Obama’s honour in Pretoria, Zuma described the relations between South Africa and the United States as “extraordinarily strong”, but said that both countries now had a duty to take them a step further for mutual benefit.

“We appreciate the trade focus of the visit. We are pleased that our mutual trade is again reaching its prerecession levels. Our priority is to consolidate and grow this trend,” he said.

Zuma anticipated that an exchange of business delegations would soon follow to consolidate Obama’s visit; he invited both US public entities and private companies to join South African companies as partners in

a number of bankable projects.

Zuma said South Africa sought partnerships that would help deepen industrialisation, create jobs and develop skills by expanding investments in the country, in line with the aims of the National Development Plan.

“We envisage investments in areas where the USA can add considerable value. These include infrastructure development, agro-processing, beneficiation of our minerals, information technology and the green economy.”

Earlier on Saturday, Obama and Zuma held a joint media conference during which they expressed a common goal of expanding trade.

“The stage is now set for a lot of work to be done to further deepen our bilateral relations and also to promote democracy, peace and development on the continent,” Zuma said.

JUL 13 PAGE 7

NEWS All that’s happening in South Africa

Denel sign Airbus agreement South African defence manufacturer, Denel has signed a R157 million agreement with Airbus to manufacture tail plane parts for the A400M strategic airlifter.

The contract, lasting eight years, will begin production in the next few months with the first finished parts being shipped to Airbus’ manufacturing plant in Stade, German in August 2013.

According to Denel Group chief executive officer, Riaz Saloojee the contract demonstrates the confidence that international manufacturers have in South Africa’s aerospace industry.

“We have proven ourselves to be a reliable and innovative top tier supplier to one of the most sophisticated aircraft manufacturing programmes in the world,” he said in a statement last week.

“Airbus’s decision to place a third major order with

Denel shows satisfaction with the quality of our design and manufacturing processes and our ability to deliver on time and within budgets.”

The deal includes the manufacturing of spars, ribs and a connecting plate known as the sword; all constructed from carbon fibre composites and covered with a metallic skin before being added to the internal tail structure before the plane is assembled.

“The vertical tail plane is a flight critical part of an aircraft of the size of the A400M and contributes to its unique ability to land and take off carrying payloads in excess of 35 000 kilograms,” the company said.

Denel Aerostructures has also just completed a relocation of its operations to one location, which will cut costs and improve efficiency, as well as position the company to take on more manufacturing work.

Mercedes-Benz SA wins award Mercedes-Benz South Africa’s manufacturing plant in East London was awarded silver in the 2013 automotive Initial Quality Study (IQS) by American market research firm JD Power and Associates.

The survey, now in its 27th year, examines new car buyers in the US and saw Mercedes-Benz’s East London plant win its fifth consecutive award for the top assembly plants in the Europe-Africa region.

The award was given for the production quality of new vehicles at the plant, and Mercedes-Benz SA was the only African manufacturer to win this accolade; the company now displays one platinum, two gold and two silver awards in its trophy cabinet.

The plant was only one point behind the category’s gold award winner, which scored 23 problems per 100

PAGE 8 FEB 8 JUL 1313

vehicles (23PP100), and a point ahead of the MercedesBenz sister plant in Sindelfingen in Germany.

“The score is an indication of the consistent and sustainable strides we are making as a local manufacturer to create products of the highest build quality, that are safer and more carbon-friendly,” said Mercedes-Benz South Africa’s vice president for manufacturing, Arno Van der Merwe.

The plant’s performance in the 2013 survey improved by four points from last year, “This progression also clearly shows the rate at which the global industry is improving, and the pressure to run a tight ship at our plant in terms of reliability, efficiency and quality in order to remain competitive,” Van der Merwe said.

NEWS

Aspen in Dutch pharmaceutical deal South Africa’s Aspen Pharmacare has signed a R10 billion deal with Dutch pharmaceutical firm, MSD to acquire an active pharmaceutical ingredient (API) manufacturing business in the Netherlands and satellite office in the United States.

Aspen, Africa’s largest generic pharmaceutical company and ninth largest in the word, says that the deal is part of its strategic plan to further globalise its business, increase its representation across a number of additional territories and provide support to its growing global presence.

“This transaction provides a platform to contribute to the achievement of this strategic intent by enabling Aspen to access a niche range of APIs and finished dosage products,” said Aspen Group chief executive, Stephen Saad.

The API business sites are made up of manufacturing operations based in Oss, parts of the

Moleneind and De Geer sites and the Boxtel site in the Netherlands, as well as Sioux City, Iowa in the US. “The products manufactured at the sites fall into two categories, namely biochemicals, where biological processes are involved, and chemicals where the process is fully synthetic,” the company said in a statement on Thursday.

The deal also includes the option to acquire a portfolio of 11 branded finished dose form molecule products from MSD, covering a range of treatments such as hormone replacement therapy, oral contraceptives and anti-coagulants with brands such as Benutrex, Orgaran and Ovestin, among others.

The deal is expected to become effective on 1 October, and if Aspen take the option to acquire the finished dosage products, it will take effect on 31 December.

CSIR sign agreement with Boeing South Africa’s Council for Scientific and Industrial Research (CSIR) has signed an agreement with US aerospace giant, Boeing to collaborate on the research and development of titanium powder for industrial manufacturing processes in the aviation industry.

“This mutually beneficial agreement, bolstered by South Africa’s rich titanium ore reserves, supports the nation’s long-term economic development goals that include the supply of titanium to many industries, including aerospace,” the CSIR said in a statement.

The CSIR has developed and patented technology that converts titanium tetrachloride to titanium powder, and Titanium Centre of Competence director, Willie du Preeze says that Boeing’s experience will compliment that of the CSIR. “Boeing’s competencies and experience regarding the applications of titanium in aerospace parts and structures will hugely complement the CSIR’s drive towards commercialisation of the titanium technologies.”

The centre of competence is hosted by the CSIR and features collaboration with the national science department, various South African universities, science councils and commercial entities.

A titanium pilot plant was launched in Pretoria last

month in a partnership between CSIR and the Science and Technology Department and will assist in the up-scaling of the technology and the agreement with Boeing.

“It is a breakthrough in the production of titanium metal powder using a novel continuous process, instead of the more conventional batch process,” Science and Technology Minister, Derek Hanekom said at the launch of the plant.

The success of the pilot plant will drive the commercialisation of the country’s titanium beneficiation strategy and is expected to stimulate development in various sectors.

JUL 13 PAGE 9

Entrepreneur

Are social entrepreneurs the future?

By: Joe Forshaw Social entrepreneur, Sizwe Nzima, is helping to solve the problem of overcrowded health care facilities in the Western Cape through his innovative business, Iyeza Express.

PAGE 10 JUL 13

Entrepreneur This month’s entrepreneur is widely regarded as a ‘social entrepreneur’’, meaning he pursues innovative solutions to social problems. Sizwe Nzima, an inspirational young business man from the Western Cape township of Khayelitsha, has started a business called Iyeza Express and the core function of the small start-up is to collect chronic medication from clinics and deliver it to residents in the local area.

The inventive business is addressing the long-standing social problem of overcrowding in public health facilities.

Instead of standing in long queues for hours, Nzima’s Iyeza Express collects vital medication from local clinics and delivers them by bicycle to Khayelitsha residents, at their homes.

The idea has proven itself to be a time-saver, a real help to less able people, an eco-friendly initiative and profitable for Nzima and his colleagues.

Nzima has two business partners and he told MediaCludSA that the group is committed to building the economy and solving social issues. “We are all about social change and we are coming up with business ideas that can change society, help our community and uplift the economy.

“Business isn’t just about making money, but also about bringing about positive change.”

After completing an intensive business training course at the Raymond Ackerman Academy, Nzima started the company in May 2012 and instantly began addressing the problem of busy clinics, a problem which he witnessed personally.

“I used to collect medication for my grandma for three years and experienced first-hand what happens.

“I thought to myself that I must do something and that surely there must be a need for a service that would streamline the process.”

Nzima discovered that while there are charities that collected medication for elderly or bed-ridden patients, there was nothing in place for the working person who was being forced to waste working hours queuing for medication.

“These were people who would happily pay for affordable delivery of their medicine, allowing them to save their sick leave – if they get any – for days when they are really ill.

“The service encourages people to go to work and stay healthy as they aren’t tempted to stop taking their life-saving medication because they have run out,” he said.

“What I’m doing is helping to improve people’s quality of life and life expectancy.”

Clients of Iyeza pay a fee of R10 per collection and medicines are currently collected from Michael

Mapongwane Hospital and the Site B District Hospital.

The business had around 50 customers at the end of 2012 but since its establishment Iyeza has grown significantly and today has over 250 customers, gaining Nzima global recognition and respect.

At the end of May it was announced that Nzima had gained a place on Forbes Magazine’s 30 under-30 Africa’s best young entrepreneurs list, a compilation of Africa’s best and brightest across real estate, financial services, manufacturing, media, tech, green tech, healthcare, agriculture and fashion. Forbes says of the names on the list: “Together, they represent the entrepreneurial, innovative and intellectual best of their generation.”

The young entrepreneur already has plans in place for further expansion and he is looking to bring his services to other parts of Cape Town and, eventually, roll out on a national basis.

“For me, this is a national problem and it needs a national solution. The sky is the limit,” Nzima told MediaClubSA. Nzima has also announced that he and his partners are looking into initiatives surrounding recycling and youth education on gang membership.

“I believe young people have the power to change the world, if the youth can understand this, they will stop focusing on things like drugs and crime. We can change the world, make it safer and improve our economy in this way,” he said.

This entrepreneur and his ideas are truly having a positive effect on people in need and this is refreshing in a time where most entrepreneurs are driven solely by profits and margins, no matter what the cost.

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“What I’m doing is helping to improve people’s quality of life and life expectancy” JUL 13 PAGE 11

INNOVAtion

Walking & talking

By: Christian Jordan

Anthony Mutua is a young inventor from Nairobi, Kenya. He became well known in May last year when he revealed a brilliant innovation that allowed users to charge their mobile phones from a chip placed in the sole of their shoes.

In 2012, a young Kenyan innovator unveiled a breakthrough that could have huge impacts on mobile phone usage throughout the world.

Anthony Mutua, a graduate of Mombasa Polytechnic University College, has built a phone charger into a shoe, allowing the charger to harness kinetic energy generated through walking or running to power up a cell phone.

Presented at the Kenyan Science Technology and Innovation Week in Nairobi last year, the innovation drew a lot of attention and has since gone on to attract praise from high-profile admirers from all around the world.

Google Chairman, Eric Schmidt, one of the world’s richest men and most knowledgeable businessmen stated that the Kenyan idea was ‘an innovation from the ground up’ and David Ngigi, a senior science secretary with the National Council for Science and Technology (NCST), said that the Council will help finance Mutua’s idea so it can be commercialised.

“We have been financing the development of ideas to prototype levels but because most innovators lack funds for commercialisation, these innovations never reach the market so we are changing this,” Ngigi told Kenya’s

PAGE 12 JUL 13

Daily Nation.

So how can a shoe charge up a cell phone? Well, Mutua has developed an ultra-thin crystal chip that generates electricity when put under pressure.

“The electricity is generated by the act of walking and running, and can be harvested in two ways,” Mutua told the Daily Nation.

“It can charge phones via a long cable to a pocket while the user walks or the other alternative is to charge the phone immediately after a walk because the crystals have the capacity to store the electric energy.”

INNOVAtion Mutua told the media that the device can be used in any type of shoe except for bathroom slippers and can also charge multiple devices at once; good news for people with more than one handset.

The idea has been patented by Mutua and the Kenya Industrial Property Institute and is exciting for joggers, walkers, herdsmen and gym enthusiasts as the more you work, the more electricity you generate.

The actual chip itself is reported to cost only Ksh3,800 (R457) and after a Ksh500,000 (R60,185) investment from the NCST, development of a commercial-ready prototype is now well underway.

It is estimated that to have a shoe fitted with the device, you will have to pay around Ksh4000 (R470) or if you want to travel to the Nairobi central business district and have the device fitted by Mutua himself, you will pay slightly more and get a two and half year warranty (excluding theft or loss).

“In case the shoe is worn out you can always transfer it to the new one,” said Mutua.

This innovation will have huge effects on cell phone usage in Kenya and further afield. It is a well-known fact that cell phone usage in Africa is booming with the majority of personal internet access done through phones.

With over 90% of the population in countries such as

Cote D’Ivoire, Senegal, Egypt, Ghana and South Africa owning a mobile phone, initiatives like this are going to become must-haves, especially where energy is not as easily accessible as it is in other parts of the world.

The crystal chips are eco-friendly as they do not produce harmful by-products and they encourage walking or running rather than taxi use or short drives.

The real beauty of this product is in its universal appeal; you can see this being popular in cities across Africa but also in the major cities of the world. Perhaps it will not be long before you go into the gym and see charger cables coming from jogger’s shoes charging phones, tablets and all types of portable devices.

When the innovation is commercialised and put to a mass market, it will be interesting to see what sort of feedback customers give. Is this African invention really the future of mobile power?

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“The electricity is generated by the act of walking and running, and can be harvested in two ways”

JUL 13 PAGE 13

Gadget Corner

High-flying boys toys

By: Joe Forshaw With computer games taking over the lives of the youth, outdoor recreation is somewhat losing its appeal these days but there are some amazing gadgets out there which are revitalising peoples love for the outdoors. We have found four examples of the best kit around that will leave you with an empty wallet but filled with unique experiences and memories.

Maverick LSA Flying Car Although all of the inventions discussed here have an element of danger about them, that is what makes them attractive and the Maverick LSA Flying Car promises fun and drama in abundance.

Developed by creative non-profit organisation known as the Indigenous Peoples’ Technology and Education Centre (I-TEC) and manufactured by Beyond Roads LLC, the Maverick LSA Flying Car is designed to be an easy-tooperate vehicle capable of travelling on land, in the air and on snow.

When on the road, the car can reach 100mph thanks to a 2.5l Subaru engine. It has the look of a vintage miniroadster. When in the sky, a Powerfin 5-blade composite propeller gets the flying car up to an airspeed of 40mph. It can fly for around three hours or 450 miles at up to 10,000 feet using parachute-style deployable wings.

Although the Maverick is still undergoing fine tuning after a recent crash in Canada in which no one was hurt, you can order one for around R996,000 but you will need a full driver’s license and a sports pilot license or more with a powered parachute rating.

“The Flyboard is the reference in extreme and leisure sports” PAGE 14 JUL 13

Gadget Corner Can-Am Commander X 1000

Zapata Racing Flyboard You will have seen the Flyboard in music videos, in online adverts and on technology shows and this innovation is fast becoming one of the most sought after experiences for the wealthy and adventurous.

Developed by Zapata Racing (a jet-ski racing company) in spring 2011, the Flyboard quickly took over 2.5 million youtube hits in just two weeks.

Can-Am is the ‘open road’ division of BRP (Bombardier Recreational Products), the world leader in the design, manufacturing, distribution, and marketing of motorized recreational vehicles and powersports engines.

Recreational vehicles such as quad bikes, trikes, buggies and scramblers have been popular in South Africa for many years because of their ability to handle tough conditions and difficult terrain especially in lessdeveloped areas.

The Can-Am Commander is a side-by-side, off-road, versatile sports vehicle. It comes with a 1000cc, 85 hp engine and is capable of carrying up to 272kg without performance being affected. The Commander can conquer gravel, mud, dust, tarmac, forest, field and pretty much everything thrown in front of it.

This is not the first Commander and improvements have been made on previous models including a hugely more comfortable cab and a brilliant DPS (Dynamic Power Steering) system which both contribute to a smoother, easier ride. Starting at around R175,000, this beast is more reasonable than you may have expected.

The Flyboard uses jet-ski engine technology to channel water from a base-board, through an 18m long pipe, and fire it through power hoses attached to a user’s hands and feet. This allows for propulsion into the air and under the water which has led to the device being likened to an Iron Man or Aqua Man suit.

All you need to operate the Flyboard is an ocean, sea, lake or pond with a depth of at least four metres and the capital of around R70,000. It is forbidden to use the Flyboard in a swimming pool but if you want to test one out, there is a global distribution network with trial facilities available.

In the states, the Flyboard is becoming very popular in regions with holiday resorts such as Florida and California and you may even see Justin Bieber testing his.

Developer Franky Zapata claims the Flyboard is now “the reference in extreme and leisure sports.”

Cloudhoppers Hot air ballooning is a long standing sport that started with man’s first flight in 1783. Today, the activity has developed into a competitive movement with various types of balloon manufactured and used.

Cloudhoppers are one man balloons that do not have a basket but rather a harness or seat, like a parachute.

Hoppers can range in size from around 14,000 to 35,000 cubic feet and have maximum flight times of around an hour and a half.

A cloud hopper is easy to manoeuvre, you can take off and land in small spaces, and you can get the balloon in the back of your car. They start at around R155,000 and reputable sellers include Lindstrand Balloons and Cameron Balloons in the UK. Perfect for a quick flight over the farm or countryside, floating gently in the breeze!

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JUL 13 PAGE 15

Destination Director

Unique luxury awaits you…

By: Lauren Grey and Joe Forshaw There are millions of hotel rooms in this world, some great, some good and some bad but the ones that are difficult to find are the ones which take your breath away, which inspire you and help you feel moved yet relaxed.

We have found four of the more unique hotel experiences from around the world which certainly have the wow factor – if you can afford it!

Conrad Maldives Island Resort Hotel The Conrad Resort, located on the islands of Rangali and Ranalifinolhu in the Maldives, is a six-star luxury resort with some very attractive selling points.

Apart from the magnificent tropical location, with crystal clear seas and golden sunshine, the hotel has three separate resorts – a quiet, ‘hideaway’ style resort on the island of Rangali, a livelier resort packed with facilities on the Ranalifinolhu and an overwater spa, a resort in itself, which is set 100m off the tip of the main island.

The hotel is also home to the Ithaa Undersea Restaurant, the only all-glass undersea restaurant in the world which, on special occasions, can be converted into a bedroom for the most unique of sleeping experiences.

The resort has a cheese bar with over 100 selections available, a wine lounge with over 20,000 bottles of vintage and new discoveries and at over R20,000 per night for the underwater room, you can expect the very best!

stress melts away; guests can relax and renew their energy while surrounded by unspoiled nature.

A weekend at Treehotel offers a variety of both summer and winter activities, but many guests choose to simply enjoy the quiet, timelessness and harmony that are found in the trees and surroundings; a good book, a magical view and stylish accommodation are enough to create the feeling Treehotel is all about.

Prices start from around R6716 per night, with infants between 0-2 going free; prices include a buffet breakfast and there are facilities for helicopter and snowmobile arrivals.

TreeHotel, Sweden The Treehotel, located in Harads near the Lule River, offers a unique hotel experience for those seeking serenity, relaxation and sophistication.

The forest area in which the Treehotel is situated, consists of five completely unique treerooms; The Cabin, The UFO, The Blue Cone, The Bird’s nest and The Mirrorcube, all of which are suspended 4-6 meters above ground with spectacular views of the Lule River.

The idea behind Treehotel is to offer high-standard accommodation in a harmonious place where daily PAGE 16 JUL 13

Peter Lundstrom, WDO - www.treehotel.se

Destination Director

© 2013 Conrad Hotels and Resorts

Four Seasons Resort, Bora Bora, French Polynesia The island of Bora Bora is a destination deeply entrenched in the mind of the romantic traveller; with its crystal clear lagoon, tropical beaches and luscious green mountains it has been dubbed the ‘Pearl of the Pacific’.

Forming part of the French territory of French Polynesia, Bora Bora is surrounded by a beautiful coral reef, and while close to its neighbouring islands, is in a very remote part of the world.

Whilst in Bora Bora, visitors can scuba dive into the island’s incredible underwater world, enjoy a Jet Ski guided ride on the lagoon or simply relax on its tropical beaches.

The most popular accommodation whilst in Bora Bora is an overwater bungalow, some of the best of which can be found at the Four Seasons Resort in Motu Tehotu, which allows visitors to stay right in the heart of the lagoon; waking every morning to tranquil sound of lapping water.

The hotel is five star rated and raved about in reviews with prices starting from around R6000 per night.

The Igloo measures approximately 2000 square metres and the entire exterior and interior is made of snow and ice; the rooms, the beds, even the glasses in the ice bar.

Apart from its 30 bedrooms, the Igloo Hotel houses suites, an ice-chapel, an ice-bar and several lounges.

The breath-taking hotel has an inside temperature of between -4 and -7 degrees. However, guests are sleeping on reindeer hides inside sleeping bags that can stand -30 degrees, so there is no risk of getting cold.

An overnight stay in the Igloo Hotel starts at around R3800 per person and includes a morning sauna, breakfast buffet and bus transfer to/from Alta town centre.

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The Igloo Hotel, Sorrisniva, Norway The world-famous Igloo Hotel, situated in Sorrisniva is the only one of its kind and will be built for the 15th time in 2014, ready for its open season between January and mid-April; perfect for those looking to escape the summer sun and experience something truly unique.

www.sorrisniva.no

JUL 13 PAGE 17

Dust off your dancing shoes…

Pabi Moloi

By Joe Forshaw

On July 10th, Strictly Come Dancing will return to our TV screens courtesy of SABC3. It was announced recently that the show will have two brand new hosts in the shape of Power FM DJ Pabi Moloi and comedian Marc Lottering.

Pabi spoke to IndustrySA about the sixth series of the show and said that excitement is building…

PAGE 18 JUL 13

Pabi Moloi You must be thrilled to be chosen as co-presenter of Strictly Come Dancing?

I’m very very excited. I’ve always been a fan of the reality TV shows, it gives people a chance to show off their skills but this takes it to a different level. There are people who we have never seen dance before trying to be the best dancers in the country so I am excited! I think it’s going to be entertaining and fun and I’m really looking forward to it.

You’ve done a lot of similar work before, is it difficult to switch between TV and radio presenting?

I started in television, doing a show called KTV when I was 11 years old. I was presenting, interviewing heads of state, interviewing foreign TV presenters and actors and all kinds of things like that.

Television is where I’m the most comfortable. It took me a good while to get used to radio, not the other way around.

Are you excited to work alongside someone like Marc?

Absolutely. His brain, his sharp timing, I’m looking forward to being around all of this just as a fan of his.

To work with someone like this is just a dream.

This is the sixth series in South Africa. Do you think it will have the same reach and impact this time around?

I think it’s different every year because there are different stars dancing every year. It’s a delicate balance of getting just the right group of people together and luckily that’s not my job! We have great producers handling that. This is the first season with Marc and myself as presenters so hopefully we will bring something a little fresher and something new to the programme.

The list of contestants has been finalised and it’s very exciting!

How did the whole Strictly thing come about for you?

They’re never really glamorous stories. It’s not like I went to a party and the producer saw me dancing and thought I would be perfect, it’s not like that, it’s a very stock, standard audition process. They gave me a call and said they’d like to see me, I went in and did a casting, they liked what I did in the audition and gave me the gig.

Away from Strictly, what else is on the horizon for you right now?

Well, a brand new radio station and a new TV show is enough for my life right now. A lot has changed in the last few weeks in my world. I’m always working with my foundation, we go out and do career expos with kids from disadvantaged high schools and that takes up a lot of my time.

Finally, what advice would you give to someone in media who wanted to form a similar career to your own?

Don’t be above the hard work. There is a lot of hard work, a lot of rejection and a lot of disappointment as well. Don’t think that it’s all going to happen in a matter of days, weeks or even years. You have to be very very patient and work extremely hard.

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“There are people who we have never seen dance before trying to be the best dancers in the country so I am excited”

JUL 13 PAGE 19

company report

DCD begins to harness SA’s wind power Editorial – Joe Forshaw Production – Hal Hutchison Construction of DCD’s 23,000m² wind tower manufacturing facility is now well under way at the Coega IDZ in Port Elizabeth. IndustrySA speaks to DCD Mining and Energy marketing manager, Henk Schoeman to find out more about the progress and plans for this major new facility.

In February, IndustrySA took a closer look at one of South Africa’s newest wind farm projects, the Van Stadens wind farm in the Eastern Cape. The drive towards renewable energy is gathering pace and with the governments quotas for significant amounts of the country’s electricity to be gained from renewable sources edging ever closer, the amount of work going into wind power is increasing greatly.

One of the companies now heavily involved in the renewable energy industry, especially with wind power, is DCD Mining and Energy, part of leading international engineering manufacturing group DCD. In December last year, we heard how DCD had manufactured the first 80m wind tower prototype for an Aerodyne turbine and Marketing Manager for Energy, Henk Schoeman, told us then that plans were afoot for a wind tower manufacturing facility to be constructed in Port Elizabeth

PAGE 20 JUL 13

and in May, after an official sod turning ceremony, construction of the facility began.

This is good news for the renewable industry as there are now stringent rules in place about the use of local content and DCD fully expect to become the industry leader in the manufacture of wind towers, providing a boost to the industry and fully localising the task. This will also result in the use of locally sourced materials from local companies, ensuring the wind towers are in fact 100% South African.

In Van Stadens, Sinovel turbines were used which had to be imported from Shanghai so localisation of the whole process is something that the industry and the government will welcome.

It has been estimated that construction of the facility will cost around R300 million and Schoeman explains that progress so far has been fruitful.

“Construction started in March this year and all the

DCD Mining and Energy

“The factory will be finished and ready for manufacturing

by January 2014” preliminary work is complete. The foundations are going in and we have started with steel work. By October we will have something that looks like a building.

“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.

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

“The Industrial Development Corporation (IDC) is partnering with us and this shows the government’s commitment to the project and industry. It is great for us to

have them as a shareholder; it is something we pushed hard for.

“The partnership between DCD Group, the IDC and Coega Development Corporation is evidence of a combined effort to provide sustainability and growth to the local renewable energy sector,” says Schoeman.

JOB CREATION One of the drivers behind the development of not just the DCD wind tower factory, but the entire Coega IDZ (Industrial Development Zone), is to create employment for the Eastern Cape and specifically the Nelson Mandela Bay Metropolitan Municipality.

“From the community perspective it is an important investment,” says Schoeman. “It is important for the Eastern Cape as it will create around 600 jobs during construction and we will employ around 150 operational staff when the factory is up and running. ...continues on page 24

JUL 13 PAGE 21

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.

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 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.

.

Plate Mill at ArcelorMittal South Africa

Rebar produced by ArcelorMittal South Africa

company report

...continued from page 21 In the future we will create a supply chain and support smaller, local companies to assist with the supply of components to the factory. It is without a doubt a great injection of work and opportunity for the local community.”

The CDC (Coega Development Corporation) reiterated the importance of the investment with Ayanda Vilakazi, head of marketing and communications saying: “The benefits to the local economy will penetrate beyond the local skilled jobs and training to include logistics opportunities and additional value chain opportunities, thus creating a new industry in the Eastern Cape.

PAGE 24 JUL 13

“Moreover, investment leads to infrastructure development particularly with regard to rail and roads, and inland logistics take the incoming loads into account.”

PROGRESS SO FAR As mentioned above, there was an official sod turning ceremony in May and since then, work on the facility has come a long way.

“The factory will be finished and ready for manufacturing by January 2014. From February, we will supply towers for round two and from January 2015 we will supply towers for round three of the Government’s IPP program,” says Schoeman.

DCD Mining and Energy “We want to localise the manufacture of wind towers and we will manufacture for the OEMs to their specific requirements.”

When the factory is fully up and running in January next year, the focus will be solely on the manufacture of wind towers but Schoeman suggests that further down the line, the company could look at manufacturing more parts for the renewable wind energy industry.

“With DCD, we are currently focussing on the energy markets including renewable, coal, nuclear, hydro and gas power stations. With renewable energy, we’ve proven that we can manufacture towers, blades and assemble the nacelle. In the future we will look at other opportunities to support the localization of the Energy market.

“A substantial amount of research and development work has already been undertaken, and the DCD Wind Towers team is bench marking 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.”

LONG-TERM PLANS The renewable market is still in its infancy in South Africa, even wind and solar projects are relatively new and considering these are long-standing industries in devel-

company report oped countries, the South African market still has a lot to learn and a lot of opportunities to explore.

Away from South Africa, there are obviously a huge amount of opportunities cropping up, especially on the continent and Schoeman suggests that DCD could definitely service markets in other countries following its initiation at home, in South Africa.

“Currently, the factory is a new thing and we want to become commercially active and competitive in the local market. We definitely would like to supply towers to African countries especially southern countries as the logistics become easier. If it makes sense for us to offer towers to other markets and we can be competitive then yes, we would like to do so.”

This is not an unrealistic goal and considering the location of factory, right next to the deepwater Port of Ngqura, with Transnet still investing heavily in rail links to the IDZ, logistically the facility is in the perfect position to grow with the industry and place DCD Wind Towers, and the group as whole, in the perfect position to take full advantage of this very important

“It is important for the Eastern Cape as it will create around hundreds of jobs during construction”

PAGE 26 JUL 13

and quickly growing industry.

.

Steel service at its strongest.

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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

PAGE 28 JUL 13

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: Driving manufacturing in SA

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

JUL 13 PAGE 29

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

PAGE 30 JUL 13

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 33

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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PAGE 32 JUL 13

GRW: Driving manufacturing in SA

...continued from page 30 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 36

“We have a new service centre opening in July in Johannesburg”

JUL 13 PAGE 33

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).

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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.

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company report ...continued from page 33 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

PAGE 36 JUL 13

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: Driving manufacturing in SA 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.”

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Making use of our skilled staff and innovative designs, we strive for customer satisfaction.

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

PAGE 38 JUL 13

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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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.

PAGE 40 JUL 13

“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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company report

Eradicating

SA’s housing backlog Editorial – Lauren Grey Production – Hal Hutchison

Property development company, Calgro M3 has been assisting government to help eradicate South Africa’s housing backlog, which is currently at 700,00 units, since 1995. IndustrySA caught up with Business Development Director, Derek Steyn to find out more about the company’s history and how it plans to tackle the problem.

Trade and industry within South Africa continues to develop at a steady rate, bringing both financial stability and foreign investment into the country but one issue that remains a concern for the government however, is the provision of affordable housing and formal housing in general.

Between 1994 and June 2011, the government built over three million homes for South Africans, giving shelter to over 13 million people, but investment from the private sector alone is not enough to completely eliminate the housing problem.

Property development company, Calgro M3 has been contributing to the development of housing within the country for the past 18 years; helping to slowly – but surely - eliminate the problem.

PAGE 42 JUL 13

Established in 1995 by brothers Derek and Deon Steyn, Calgro M3 immediately set about filling a noticeable gap in the affordable housing market, “our third brother Douw joined the company a year later, we all have backgrounds in quantity surveying so we set about targeting South Africa’s housing problem together,” explains Business Development Director, Derek Steyn.

Initially, the company was named Calgro Homes and focussed on project management in low cost housing, but after just one year, Calgro Homes had 60 houses under construction and another 120 in various stages of development.

The company’s success allowed it to expand into new markets as Steyn explains, “Around the year 2000 we expanded a little into mid to-high income housing, such

Calgro M3

“There is still a huge market still to be serviced in South Africa … the 40,000 units that we have in our current pipeline are not really making any difference in the providing of housing.”

as your typical cluster type development but after the market fell through in 2008, that’s when the focus shifted back to the lower income/affordable housing.”

Steyn says that although Calgro M3’s main focus continues to be affordable housing, a maximum of 20% exposure is still given to mid to-high income developments.

COMPANY MERGER One of the company’s most monumental milestones came in 2001, when Calgro Homes joined with M3 Developments, a company owned by Malherbe brothers Ben Pierre and Brand - also quantity surveyors.

“Calgro M3 started as a joint venture between Calgro and M3 Developments,” explains Steyn, “we were both

tendering separately on the Firenza project in Randpark Ridge, a high income cluster development, until we decided to do a joint venture. So we started as a joint venture but then we thought it would be beneficial to everyone involved if we just merged and made it a more formal arrangement.”

The newly formed company completed the Firenza project in 2001, which was made up of 71 units as well as infrastructure including roads, water works, sewerage and electrical works; with a project turnover of R53.3 million, which was a significant development for the time.

In November 2007, Calgro M3 was listed on the AltX board of the JSE and began development of its first integrated residential project, the 2800 unit Pennyville development, located south west of Johannesburg,

JUL 13 PAGE 43

company report

“Part of our business is to ensure we keep a strong relationship with government, especially with the lower income because all of our projects have got a 30-60% subsidised housing portion in it”

consisting of four different housing options; 1600 fully subsidised RDP houses, 600 Johannesburg Social Housing Company (Joshco) affordable rental units, 200 Joshco social housing units and 800 mid to high income rental units offered by investors and banks.

After the project’s completion in 2010, many more were commissioned, including the Jabulani development, the Brandwag social housing project, the Scottsdene project and the Fleurhof Ext 2 integrated project, to name a few.

BEST SOCIAL HOUSING PROJECT 2013 Fleurhof is a long-term project situated south west of Johannesburg next to the existing Fleurhof ext 1 residential township, and is set to be one of the largest integrated housing developments in Gauteng, with 9558 units.

The project, which has already won the Govan Mbeki Award 2013 for Best Social Housing Project in Gauteng, comprises various types of residential units and forms of tenure that have specific economic target markets.

The development will include infrastructure such as

PAGE 44 JUL 13

roads, water, sewer, reticulation and storm water facilities, extension of Westlake Road - linking Soweto with northern suburbs-, four business centres, seven crèches, five religious sites, one community centre, three schools and between 20-30 parks.

Steyn explains that development of the project is well underway and most of the units are already sold, “we are extremely happy with the way this project is going, in fact, I’d say we will be out of Fleurhof in four years; everything will be done, including construction. We are busy servicing 2,500 opportunities as we speak, but most of the units are pre-sold.”

Aside from creating thousands of new homes across South Africa, Calgro M3 also make conscious efforts to help reduce the country’s carbon footprint with several green initiatives going into its developments.

The project team for Fleurhof is currently investigating various potential green initiatives to assess the viability of certain energy saving technologies such as solar water heaters, heat pumps and improved insulation for

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company report the various types of housing units; residential recycling projects, food gardening and urban greening initiatives are also being looked at.

Besides the green component, the added benefit of these measures will also reduce electricity demand by the development and make the township socially and visually more attractive.

Steyn says that although the company is conscious of its efforts to reduce the carbon footprint, it can be extremely difficult to implement green initiatives into lower income housing due to costs.

“It is very difficult to incorporate any green initiatives for low income developments, purely because of cost; to go green is very expensive. Our higher market units are very green, but we do what we can for the lower income, for example heat pumps which can provide a 60% saving on electricity, which makes your electrical requirement from city power much less” he explains.

Aside from heat pumps, gas installation and grey water harvesting are also being incorporated into the Fleurhof project.

FUTURE PLANS Calgro M3 has become the preferred supplier for property development in South Africa, and over the past 18 years it has continued to help governments eradicate the 700,000 unit housing backlog that is rife in the country.

“The backlog in low income housing is enormous and the lowest statistics according to ABSA Bank is that in the bonded market, therefore in the market up to R50,000 there is still a 700,000 unit backlog and only about 25,000 units per annum are being delivered” explains Steyn.

“Part of our business is to ensure we keep a strong relationship with government, especially with the lower income because all of our projects have got a 30-60% subsidised housing portion in it. The RDP’s, social housing etc. are all government financed so it is crucial that we have a strong relationship with them; both local and national government.”

These long-standing relationships have ensured that Calrgo M3 remain the preferred supplier within the property development market, and Steyn says that although the company has received invitations for projects in neighbouring countries, the demand in South Africa is so high that they have no reason to explore new markets just yet.

“We are constantly approached by people with projects in the Democratic Republic of Congo, Ghana, Mozambique and Zimbabwe, but we’ve got such a lot of work on our doorstep that our view is if we were really stretched for work, Africa would be a fantastic

PAGE 46 JUL 13

opportunity, but the market is so strong and the demand is so big here we haven’t got a reason to venture into fairly unknown and possibly high-risk markets just outside of South Africa,” explains Steyn.

“There is still a huge market still to be serviced in South Africa, the market here is absolutely gigantic, and the 40,000 units that we have in our current pipeline are not really making any difference in the providing of housing.”

“In regards to new markets opening up in South Africa, such as the Social Housing market segment, government has committed funds for 80,000 units over the next five years in this market segment and with only approximately 3,500 units being delivered per annum, the market is enormous.”

PERFORMANCE Since its inception in 1995, Calgro M3 has created in excess of 5,000 jobs in line with government’s drive for job creation and established itself as the market leader in the low income and integrated development sector.

The company has reported a 55% revenue increase in 2013 from R515m to R798m, and Steyn says that the key its success is ‘hard work, dedication and perseverance’.

“We are not concerned about that industry or our position in the market due to various reasons, the only main concern for the company is actually the fact that the number of opportunities is so high,” he says.

In 2012, Calgro M3 was listed on the JSE’s main board and now holds the vision of being the housing developer and partner of choice by consistently delivering homes and projects of the highest quality.

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company report

Turnkey storage solutions Editorial – Joe Forshaw Production – John Cliff

Since 1994, Universal Storage Systems has been providing first-class racking, shelving and storage solutions to companies and industries across the country. Sales Director, Jan Breytenbach, tells IndustrySA more about what makes the company a success.

Last month, we discussed the importance of supply chain logistics and the negative effects that can arise from having an unproductive distribution system. This month, we speak to Universal Storage Systems, a Johannesburg based company, helping local, national and international clients to ensure they are making the most of their space and offering quality solutions to storage problems.

In February 2012, Universal Storage Systems completed their part in the development of the UTi Pharma distribution centre at Linbro Park, Gauteng.

The company installed the country’s first clad rack building which was locally designed, engineered and manufactured.

The facility is used by UTi Pharma for the storage of pharmaceuticals and has the ability to store over 38,000

PAGE 48 JUL 13

pallets. This type of innovative build allows for flexibility and expansion as the system uses racking as the main structure, with cladding sheets added for walls and roof.

Rack clad builds offer optimal cubic area storage space, are relatively fast to erect and they are cost effective.

Universal Storage Systems Sales Director, Jan Breytenbach, tells IndustrySA that the UTi Pharma project was a one of a kind.

“The project with UTi Pharma was a first for us and a first for South Africa. Everything was new on this project; we had to design tools from scratch. This is one of the flagship projects that Universal has completed.

We finished at the end of February 2012 and I think it will be a while before we do something like that again, projects like that don’t come around all that often,” he says.

Universal Storage Systems

Universal build strong, long standing relationships with their clients and with UTi Pharma, the association goes back over two decades as Breytenbach explains: “It’s been a great relationship and over 21 years we have come to fully understand that our client has to service the storage needs of many leading pharmaceutical companies while ensuring that patients always get the original quality medicine they need, when and where they need it.”

So when a company decides they need a new storage solution or racking and shelving system for a new warehouse, how does the whole process work?

Breytenbach explains that Universal offers an allencompassing service, from concept to completion.

“We do a large range of products which starts with industrial shelving and racking. We also do small part storage and normal pallet racking. Pallet racking is our

core business and forms the biggest part of our work although small part shelving is also big for us. Pallet racking is the product of which we sell the most.

“We are not a storage company; we do not offer storage to clients. What we do offer is a solution to the client about storing their product in their warehouses.

“Myself or a member of the sales team will go and see a customer and they will explain the vision they have for the warehouse. We will then go in and assess the products and the available space and present the customer with an auto-cad drawing from which they can understand how everything will look. We will then go backwards and forwards until the customer is happy with all of the technical drawings and then a price is submitted. From there, an order is placed and we manufacture everything locally, we don’t import any product from anywhere.

JUL 13 PAGE 49

company report “It is important to buy local as all local products are certified so we know exactly what they can and can’t do.

It’s a full turnkey solution, from initial contact until the day we hand the warehouse back with racking installed, we handle everything.”

STRONG HISTORY Universal has a long and deep history but in South Africa its roots can be traced back to 1994 when the current management saw an opportunity and bought the company with the view of fulfilling its obvious potential.

“The company was bought in 1994 by our management,” explains Breytenbach. “They had previous experience with big companies before the opportunity came up to buy this company and in 1995 it became Universal Storage Systems.

“At that time, the company was struggling but the management saw an opportunity for the future. Since then we have been growing and growing and getting bigger and bigger all the time.

“We have shown growth since 2008 at a rate of about 32-33% annually. This year started off very slowly but after the first quarter it started picking up and now we are very busy – workwise, we cannot complain. I think the boom will last until April next year and after that we will see how the market is performing.”

There are plans afoot to continue the exponential

PAGE 50 JUL 13

growth that the company has experienced over the years and Breytenbach says that the opening of a new sales and distribution branch in Nelspruit will help to serve the growing market in Mozambique as the company looks to Africa at a time when growth and development on the continent continues to gather pace.

“We have around 140 employees. Most of the team is located in Johannesburg. We have branches in Cape Town, Durban, Port Elizabeth and a new branch which has just opened in Nelspruit. We moved into the premises on April 1st with the purpose of expanding the company’s reach.

“The north eastern part of the country is an area in which we are looking to expand so this branch is perfectly located. It’s also close to Mozambique where there is a lot of expansion happening because of the coal and natural gas reserves that are being serviced. The new branch will allow us to serve that area effectively rather than working from Johannesburg.

“We currently service Botswana and Swaziland. We have agents in Botswana that sell our products but we will also service that area from Johannesburg. A long time ago, we had an export department in Universal and we would export to Africa and the UK and we had a branch in Dubai but exchange rate problems forced us to cancel export activities.

“We are looking at avenues into Africa, especially

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Ghana, Tanzania, Kenya and Nigeria and we are looking at setting up distribution in these countries but right now we are still in the planning phase and nothing is concrete yet,” says Breytenbach.

CHALLENGING TIMES Every business has faced its challenges thanks to the global economic slowdown and Universal is no different.

Although the company has seen tremendous growth, it has also seen projects stall because of the uncertainty in the economy and tough trading conditions, especially in the steel market.

“Towards the end of last year, there were a lot of greenfield projects that we started working on but when the time came to start breaking ground, a lot of the projects were put on hold. People pulled back and decided to wait until the end of the year before looking at it again.

“Everyone has felt the pinch. With the exchange rate going up and down and the volatile steel prices, it is very difficult to plan too far down the track. The whole building industry suffers from the effects of the rand-dollar rates and steel price fluctuations.

“If steel production slows, it can have dramatic effects on the prices as the market will have to look elsewhere,

“We are looking at avenues into Africa, especially Ghana, Tanzania, Kenya and Nigeria” to places such as Malaysia and Brazil, to import steel and that brings with it import duties and all the rest,” says Breytenbach.

As mentioned above, even during the times of price fluctuation and exchange rate instability, the company has plans to expand but Breytenbach says that expansion will consist of movement into new markets, not into new products or services.

“We can always look at international markets but we don’t want to take on too much in one go. For now we will focus on the African markets and as we grow we can look at exporting again.

“Competition in Europe is tremendous; they have fantastic automated facilities and can often make products a lot cheaper. We are working towards automation but we still rely on manual labour.

“Shelving and racking is our core business.

JUL 13 PAGE 51

company report

We have an R&D department so we can look at improving our products but we will not move away from our core.”

It is this core activity that made Universal so popular over the years so it is no surprise that the company will continue to focus on what it knows. Too often we see companies diversify away from their core activities unsuccessfully and Universal will not fall into this trap.

The future holds continued investment in quality and a focus on meeting customer requirements.

“All of the manufacturing takes place under one roof at our headquarters in Johannesburg, Strydom Park.

Everything that we sell gets manufactured here.

“What separates us is quality. The way we manufacture and the quality processes are second to none. We have a lot of experienced people and this assures the customer when it comes to products. We are obviously competitive on price as well and we spend a lot of money ensuring we deliver the best product,” says Breytenbach.

This is an industry that is becoming more and more important to the South African economy and as the country continues to develop and levels of consumerism PAGE 52 JUL 13

continue to increase, companies have to ensure they are controlling their stock in the correct way with storage obviously playing a huge part in that. Breytenbach concludes by telling us that effective utilisation of warehouse space is now a vital part of business and can become invaluable to any company.

“With the growth of the population comes growth of the amount of products needed. Everything from medical to food has to get to the customer faster and more and more distribution centres are popping up. Wherever you have product, you have to store it and as land becomes more expensive you have to utilise all the space you can, you’re not paying for air. The design and use of distribution centres is now integral to the country.”

.

“Wherever you have product, you have to store it and as land becomes more expensive you have to utilise all the space you can, you’re not paying for air”

Nero Steel cc has over the past nine years become one of the leading manufacturers of mezzanine floor’s and related structural steel products in SA. This success has been in large due to fundamentally sound relationships been formed with our customer who buy and sell our products to the end user within the South African materials handling industry. This in turn creates a reputable and reliable source of supply which is delivered to the end user at a great value for money price. We believe that success is only really achieved with the formation of sound partnerships between ourselves, our customers and suppliers that ensures sustainability into the future. To date we have been involved with over eight hundred mezzanine floors of small, medium and large sizes.

We have done and continue to do work indirectly for the nationally and internationally recognized companies with astounding success. We have also been involved in high profile projects and have provided structural fabrication for the King Shaka Airport situated just outside Durban.

Two of our flag ship projects have been a 3500m2 mezzanine floor for the Grafton & Everest factory in Durban and a 2900m2 mezzanine floor for the Bravo Sleep Products factory in Johannesburg, the latter being a monumentally high single level “simply supported� structure at a height of 7.3m.

Nero Steel conforms to all SABS codes of practices relating to structural steel fabrication and SEMA codes and works in close conjunction with our independent professional engineer to ensure integrity, compliance, functionality and value for money designs that will not let you down!

company report

An affordable

choice Editorial – Tim Hands Production – Hal Hutchison

MAQ Washing Powder has quickly cemented itself as the country’s number two choice throughout the fabric care aisles and its popularity continues to rise month by month. It has been just 10 years since the opening of Bliss Chemicals, a decade during which the company has continually sought to offer consumers an effective and financially viable household alternative.

2003 was a year notable for many key worldwide events; be it the final communication between Earth and ground breaking space probe Pioneer 10, the breaking of the SARS virus that caused untold disruption throughout Beijing, or the first open-air, wicker-basket hot air balloon crossing of the Atlantic Ocean by one David Hempleman-Adams, it was year packed full of incident. More locally, it was also the marking of a significant change in the washing powder market, when Bliss Chemicals cast itself in the David role against the perennial Goliath of the sector, Unilever, and launched its own MAQ Washing Powder into the South African wholesale market.

This sudden appearance of a new choice for South African consumers had a resounding effect throughout the shelves of washing powder aisles across the country,

PAGE 54 JUL 13

with the new-found competition paying dividends for South African shoppers. Jacqueline Jacobs, Sales and Marketing Manager of Bliss Chemicals, details how this change was sparked by the launch of the company’s product; “When it became obvious that MAQ Washing Powder was making inroads into retail, the price of washing powder in the market dropped, something unheard of in the industry.”

An important factor in shaping habits and trends of consumers since its arrival, the veracity of MAQ’s claims were however called into question in April 2005 following a series of highly popular radio and television advertisements. The product, when put to the test, proved itself more than worthy of its place in the market, in both its standard of washing and the whitening abilities it affords, and continued its quest to establish an affordable

Bliss Chemicals

choice of fabric care.

Now proudly billing itself as the second largest producer of washing powder in South Africa, Bliss Chemicals started commercial production in September 2003, employing at present around 680 personnel. The company is concerned principally with the manufacturing, selling, marketing and distributing of Fabric Care, Personal Care and Kitchen Care solutions in the SADC region, comprising among others Angola, Mozambique, Zimbabwe, and South Africa. MAQ Washing Powder has become the company’s real stand-out product, earning itself a household name throughout the region. It is all the more significant given that this is a wholly South African product, manufactured on the company’s premises in Industria, Gauteng.

The marketing which paved the way for MAQ’s pioneering success is a real testament to the potential of

simple, yet powerful campaigns, which in this case have seen MAQ Washing Powder move quickly from the wholesale sector into the all-important retail market.

When launched in South Africa at the bottom end of the market, Bliss Chemicals’ only promotional technique was the distribution of free samples which, although a simple ploy, led rapidly to an increased demand for the MAQ Washing Powder and a very strong wholesale presence which is still enjoyed today. So effective was the way in which MAQ was placed into the South African conscious that these strategies are being tracked by advertising agency LeoBurnett as a case study - high praise for the little ‘David’ of the market and the foothold it has subsequently gained.

MAQ’s very existence is to be credited to Bliss Chemicals Managing Director, Shoaib Iqbal, who opened

JUL 13 PAGE 55

company report

“One of the reasons JMV has grown from nothing to where we are today, covering 17,000m², is because we are a family owned company and management is in the hands of the family”

the manufacturing company in South Africa after many years of involvement in trading in Africa. Spying a gap in the South African market with the advent of ‘free trade’, Iqbal acted upon his desire to provide the South African consumer with an alternative affordable washing powder, with MAQ’s launch filling this void with its quality, branded, product widening the previously limited range of options. The knock-on effect of boosting the South African economy has also remained a notable aspect in MAQ’s success, with the company boasting exceptional growth over the ten years since its arrival on the shelves, a growth that is being sustained to this day by increased distribution at retail and wholesale level, where MAQ and Bliss Chemicals continue to receive excellent support from the South African trade.

The strong position of MAQ Washing Powder has allowed Bliss Chemicals to branch out further in its business, introducing new products at every turn in its principle facets of trading; fabric care, personal care and kitchen care.

MAQ Auto is typical of Bliss Chemicals’ approach so confident was the company of its multi-formulated automatic washing powder for use in front-loading washing machines, consumers were invited to claim a sample sachet completely free of charge, in order to ensure absolute satisfaction when eventually buying.

PAGE 56 JUL 13

Also brandishing the now inescapable MAQ label is a range of household items designed to offer that same affordable choice to South African consumers. The company’s Securex soap is an active germ protector soap, designed to keep skin hygienically clean and fresh, while its kitchen care range focuses on three key features: natural ingredients, care and efficacy.

Bliss Chemicals is very clear when it comes to the main focus surrounding its ever-growing business; the most critical aspect of its company values is still the need to be ethical in its operations. This integrity extends to its dealings with customers, suppliers, vendors and other external parties, and in turn leads to the mutual respect Bliss feels is so crucial to the way in which these parties interact with each other.

The tenacity which Bliss aims to apply to its work is reflected in its crucial donations to schools in Tlabane.

In this case, ‘going the extra mile’ meant sponsoring 25000 lapdesks to learners in Rustenburg, Limpopo and KwaZulu-Natal, and thousands more in Tlabane in the North West Province.

Similarly to his initial desire to offer South African consumers a more affordable range of household products, Shoaib Iqbal states, “We want to help tackle the shortage of desks and in this way help to improve the lives and learning conditions of thousands of school children

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and teachers.” Clearly this is a crucial initiative; it is estimated that 4.2 million children in South Africa are without this basic element in their education, and the MAQ roadshow team ensured that another basic need was catered for in the same motion - not only were the children furnished with these new writing desks, but samples of MAQ Washing Powder were also sent home with them, a charitable way to introduce yet more South African consumers to the benefits of the affordable choice.

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“When it became obvious that MAQ Washing Powder was making inroads into retail, the price of washing powder in the market dropped, something unheard of in the industry” JUL 13 PAGE 57

company report

From thread to finish Editorial – Joe Forshaw Production – Chris Bolderstone

Since 1971, JMV Textiles has been an integral part of South Africa’s textile manufacturing industry.

Managing Director, Jay Valjee, tells IndustrySA that although times have been hard, in 2013 things are looking up and new investments are going to provide a boost for the KZN based company.

South Africa’s textile and clothing industry has seen a huge decline over the past two decades. The pressure on pricing from competitors in East has increased and made the industry an unattractive prospect for many manufacturers. Even some of the long standing, large scale organisations, that once dominated South Africa’s textile industry, have fallen to the wayside because of the switch to importing from places like China and Bangladesh.

This is the same for textile manufacturing across the globe and it takes an innovative approach to business and a commitment to quality for companies to compete in the modern environment.

We have featured a select few companies in the past that have this approach and commitment, and it has seen them perform very well with real expansion and growth opportunities presenting themselves. So is this an industry with potential to boost the economy? Should we look at textiles as an area in which jobs can be created?

PAGE 58 JUL 13

JMV Textiles Founder and Managing Director, Jay Valjee, says that with the correct management, companies in this industry can definitely be successful.

“We’ve tried getting into the export market; we established warehouses in England and the States but we had a major problem – we could not outsell the Chinese.

The pricing from China is so unbelievably low that even in South Africa, the industry has been decimated. The industry is probably only 25% of what it used to be. All of the major knitters have shut up shop. The big companies have either closed or dramatically reduced their work.

The scale of decimation is unbelievable.

“We are looking into expanding into Africa but again, the Chinese have entered these markets and their prices are so low, you just can’t imagine how it’s done. I’ve been to Shanghai and a few other Chinese cities and they look like very prosperous places so I can’t understand how they do what they do and manufacture so cheaply.

“One of the reasons JMV has grown from nothing to where we are today, covering 17,000m², is because we are

JMV Textiles

a family owned company and management is in the hands of the family.”

There is very much a family feel about the JMV business and since its establishment in 1971, the company has seen multiple generations of Valjee’s family work within the business. The togetherness and unity displayed by the family is one of the drivers of the company’s success and underpins the vision of the company - to create a well-run family owned fabric manufacturing business enterprise based on value, quality and service which will be of benefit to customers, staff and shareholders.

“When my father passed away, my brother and I became the heads of the family so to speak and we’ve always operated as a family group, using our resources to grow and this is one of the reasons for our success,” says Valjee.

“At JMV we have three generations working hand in hand.

My two grandsons have joined the business together with my sons, nephews and brothers.

“I will soon relinquish control to the younger generations and one thing I have taught them is that in

unity there is strength. Hopefully we will carry on for a generation or two more.”

A LONG HISTORY JMV has faced challenges, right from the day it was established. The company has had to be flexible and adjust to the demands of the market. After starting out with the manufacturing of socks, the company switched its focus to manufacturing knitted fabrics as Valjee explains.

“In 1971 I established the company and we started manufacturing socks. That didn’t prove very profitable.

We ordered some circular knitting machines and the first arrived in 1971 and this is when the bottom fell out of the industry. I had ordered 12 machines from Wildt Mellor Bromley in Leicester, England but we had to cut the order down to three.

“We had entered an industry where knits were no longer the in thing; woven fabric was now required by the designers. At that point, we went into fabrics for the African trade. Prior to this, polyester was quite expensive

JUL 13 PAGE 59

company report and out of reach of the sections of the general population.

We bought stock yarns from South African nylon spinners and whatever they had that was refused by customers we bought. We managed to use it to make fabric for the African trade and this proved quite successful.”

To complement the production of fabric, JMV started a new business, soon after its initial inception, to manufacturer garments. “We opened a garment manufacturing branch so that we could utilise fabric that we manufactured,” says Valjee, “this also proved a successful venture.”

The garment manufacturing company, Solar Sport, forms part of the JMV Textiles group which also includes Polydye (Pty) Ltd, a yarn dyeing facility that supplies polyester, nylon, cotton, Polycotton, acrylic and viscose yarns, both dyed and natural.

As the group continues to grow, the company has recently invested in a new facility, which Solar Sport will occupy, leaving their old space for printing services.

“In order to deal with the major companies like Nike and Adidas, Solar Sport needed a world class facility. We are always expanding and we have just purchased a panel printing company so we needed more space. Because of this, we built our new facility which will house Solar Sport

PAGE 60 JUL 13

and the old premises will be turned into a panel printing plant. We do rotary printing on fabric and we do panel printing or garments.

“Until 1980, garment manufacturing was an integral part of JMV but we decided to separate the two operations and Solar Sport was created for the manufacture of garments and JMV carried on with the task of manufacturing fabric,” says Valjee.

FROM THREAD TO FINISH Following its expansion and acquisitions, JMV now offers a fully integrated service to clients. “We are one of the few, if not the only company in South Africa that works from a thread to finished garments,” explains Valjee.

This is popular among JMV’s long list of clients, a list which boasts some of the biggest chains in the country. “All of the chains including the likes of Woolworths and Edgars and all of the corporate companies are clients of ours,” says Valjee.

The company has developed a large portfolio of services and a large workforce to deliver those services and Valjee says that assistance from the government and the local community has played a big part in building up the operation.

JMV Textiles “In the last few years we have received assistance from the state so that we can buy new equipment and modernise our factories.

“During the slump, we bought machines from South African companies that had closed their doors and we continue to buy and upgrade machinery. Today, we have 50 circular machines and we produce something like 30,000m of fabric per day.

“We have a full plant for processing, finishing and screen printing. We also have a yarn dying facility where we dye cotton, poly cotton and polyester yarns for ourselves and the trade in general.

“In total we have around 600 employees. The management is spread out through these people and we draw our skills from the South African community,” he says.

The hands-on management style and the unrivalled, diverse capabilities of the group have continued to drive the business forward even through the challenges presented by the East, and even through the global economic slowdown which is still being felt throughout South Africa.

“It has caused a dent in our turnover,” admits Valjee, “the business is family financed so we’ve have to literally cut the suit according to the cloth. We have survived and this year has been an improvement. 2010 was probably our best year;

tiles ”We wish to congratulate JMV Tex iness for their on-going success and bus ir the excellence. We are proud to be years” insurance partner for the past 20

we could not turn out enough goods. Between 2010 and 2012, the slide had started and we hit the bottom in 2012 but 2013 has started promisingly and with the new things that we are going to be doing, things should perk up quite a bit.”

When the upturn in market conditions does come, JMV will be ready to supply to customers, big and small, with quick turnaround times and a high quality focus and Valjee concludes by reminding us of the advantages of looking to South Africa.

“If people want something urgently, we can deliver,” he says. “We can deliver within three weeks of receiving an order. Just shipping from China takes six weeks let alone processing an order. The chain stores know this and if they are let down they can always come to us.”

.

“One of the reasons JMV has grown from nothing to where we are today, covering 17,000m², is because we are a family owned company and management is in the hands of the family”

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company report

Overcoming all challenges...

Editorial – Roland Douglas Production – John Cliff Bafotech is the self-proclaimed ‘one stop scraper winch shop’. The Welkom based business has been serving the mining industry for the last 32 years and co-founder, Chris Boone, tells IndustrySA that right now times are tough but Bafotech has many opportunities on the horizon.

The mining industry in South Africa is like a melting pot with many smaller industries and sub-sectors thriving within it and even existing purely to serve it. There are logistics, security, equipment, recruitment, safety and a huge list of other services that are integral for the industry to undertake its daily activities.

As strong as the industry is, it has faced many challenges over the past few years and one of the major obstacles has been the global economic slowdown, a problem which has affected all businesses differently.

Prices of mined minerals have fluctuated, sales have been up and down and mining operations around the world, not just in South Africa, have felt the pinch.

One company that has been right in the middle of the industry and seen the highs and lows over the last 32 years is Bafotech, a Welkom based company renowned

PAGE 62 JUL 13

for the manufacture and sale of high quality, locally made winches and winch components used heavily by the major South African mining houses.

Bafotech Marketing Director, Chris Boone, tells IndustrySA that although the industry is under various pressures, his company is well placed to continue its innovative work and continue to build strong relationships with clients throughout the sector.

“The whole mining industry has slowed down and everyone is asking for extra discounts, squeezing you very hard for the best prices just to keep things going” says Boone. “We are fortunate as we have two very big contracts which haven’t slowed down as such. They are still getting on with mining and are not having labour unrest as yet although they are expecting some unrest in July when the major wage negotiations take place.

“If people begin to strike, that will make things very

Bafotech

tough. People still need to be paid and cash flow is so important.

“The people at Impala have been very positive about the situation and we do a lot of work for them so we don’t expect too many problems.

“This is a tough time and it is important to survive.”

ESTABLISHED OPERATIONS Mining has been one of the main factors behind South Africa’s fixation as the most advanced and richest nation and as technology has changed and new methods of mining have taken over, new players have emerged. That being said, some of the biggest mining houses have been successfully established for many years and Bafotech has been supplying products to all the big names for a long time.

“We have vendor numbers on all the mines” says Boone.

“Implats, Amplats, AngloGold Ashanti, Harmony Gold, Goldfields, Lonmin, Petra Diamonds and all the major groups. For 80% of these, we supply direct to the mines.”

Bafotech has a manufacturing facility in Welkom which is home to nearly 10000m² of workshop facilities and a repairs facility in Rustenburg which covers almost 2500m² but things have not always been so high-profile. Boone explains that in the early days, the company was just a desk and a couple of chairs; a very low-key wholesale style operation.

“My eldest brother Frans wanted to start a business in Welkom, I was living in Johannesburg at the time so I returned to Welkom and we started up. We only had a desk that was borrowed from a friend, two chairs and a computer that Frans had won in a raffle.

“I sold my car to buy a few spare parts and Frans carried on working where he was which kept us going until we

JUL 13 PAGE 63

company report picked up regular clients.

“In the beginning we were just buying and selling and as we picked up contracts our youngest brother joined us and we realised that we needed to start manufacturing ourselves as our suppliers in Johannesburg could just put up prices whenever they felt like it but we couldn’t do that with the mines so we slowly but surely started buying machines and today we have around R14 million worth of machines,” he says.

“In the beginning there were challenges. It’s like getting married, you have to scope each other out and learn how each other think. We all had our own areas of expertise and there were crossovers but Frans and I were together in business for 30 years before he passed and Pat (now MD) and I have been working together for 23 years and with our BEE partner Lesedi Rakgagon for eight years.”

While there has been expansion and growth in the product range, the core has always remained the same and Bafotech is now recognised as the industry leader when it comes to winches and winch components.

“Winches is our core business, double drum scraper winches and mono winches which are used to pull materials up so people don’t have to drag stuff behind them.

“The double drum winches are used after blasting to pull the loose rock into a box hole, then into shoots ,then to the main shaft where it is loaded onto skips and taken out of the mine through to the processing plant,” says Boone.

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THE FUTURE As with many South African companies who are experienced in the mining industry, Bafotech has plans for expansion and growth into new markets, namely the African markets. This sort of growth would obviously help the company financially and this would be helpful considering the tough economic climate. The company already has agents in Argentina and Australia and a transport division which handles all logistics requirements.

While African markets are attractive, two markets in particular are of great interest to Bafotech and those markets are Botswana and Tanzania.

“Our divisions outside of South Africa are rather small at this stage. We are trying to develop them more and more, it doesn’t help that the Rand has gone through the floor.

Unfortunately the overseas operations are not yet in a position to cover our local costs.

“We are busy with expansion at this very moment. We are looking at working in Tanzania, Ivory Coast, Zambia and Zimbabwe. It looks like Zimbabwe is settling and we always look at the stability of a country before we enter.

Zimbabwe is right on the boarder so we can truck our

goods in quite easily, we will just wait for the election to see what happens,” says Boone.

“This is a tough time and it is important to survive” LOCAL QUALITY Bafotech uses a lot of steel in its manufacturing processes and the benefit of using steel from South Africa is the guarantee of quality and the assurances that come with certain grades. Recently, there has been a peak in local steel prices and this has impacted on profits.

“We probably get 75-80% of our steel locally and the prices have gone up by between 12-20%,” says Boone. “We bring in a lot of steel from China. With the Rand-Dollar rate the way it is, it impacts on our profits in a big way but we are carrying on and doing our best.”

JUL 13 PAGE 65

company report

To accompany quality products, you need quality processes and Bafotech is well-known for meeting and exceeding international quality standards. The company is currently working towards its ISO certification and will very soon be recognised for its hard work.

“We are not accredited yet but we have employed someone to look after all the ISO certification; quality, health and safety and the environment. We’ve moved a long way in these areas although we do not have full accreditation yet. They have been and inspected and told us where to change certain things but we are very advanced with our ISO progress,” says Boone.

When the ISO certification is achieved it will mark another milestone in the company’s long history. While

PAGE 66 JUL 13

the economic difficulties discussed by Boone still heap challenges onto the industry, there will undoubtedly be an upturn in the not too distant future and when that time comes, Bafotech will be in a prime position, ready to make further strides in the sector and expand the business further, ensuring that the objective, to become the supplier of choice to the South African mining industry and the international market, is met sooner rather than later.

.

“We are busy with expansion at this very moment. We are working in Tanzania, Ivory Coast, Zambia and Zimbabwe”

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company report

The fashion name in blankets Editorial: Lauren Grey Production: Chris Bolderstone

After emigrating from Italy during the Second World War following a devastating loss to the family business, the Magni family immersed themselves in South African culture and re-built their business manufacturing quality blankets and throws. IndustrySA speaks to Managing Director, Nicola Magni, to learn more about the company’s success and the imminent challenges facing the textile industry.

Aranda Textile Mill was established in 1951 after Managing Director, Nicola Magni’s Father emigrated into South Africa following the effects of the Second World War, “We had factories in Florence, Italy, but they were unfortunately destroyed by the Germans in the War,” explains Magni, “and after the War, because of the instability in Italy, my father and his brothers decided to emigrate.

“My father came to the country in 1950, he chose a 17 acre site in Randfontein, where the factory still operates today, and in 1951 he emigrated with his family and was joined a couple of years later by his two brothers.”

Magni explains that, was it not for the support and encouragement of a local South African Colonel, the family may not have emigrated into the country, “We are very grateful to a gentleman by the name of Arthur

PAGE 68 JUL 13

Aiken, who was a Colonel in the South African army during the Second World War” he explains.

“Arthur was stationed on one side of the river Arno in Florence with the South African troops and my family was on the other with the retreating Germans. He later became Chairman of Barclays bank and Senior Partner at Aiken and Carter, a successful Auditing firm; he gave us a substantial overdraft facility and encouraged us to come to South Africa. We brought our machinery and expertise, and it has been a wonderful relationship ever since.”

With encouragement from Colonel Aiken and the technical know-how of its founding fathers, Aranda Textiles quickly established itself as one of South Africa’s leading textile manufacturers’. The company now has two modernized factories utilizing state-of-the-art

Aranda Textiles

technology which is run in a vertical operation, consisting of fibre dyeing, spinning, jacquard and dobby weaving, finishing, make-up and warehousing.

QUALITY PRODUCTS Aranda’s main focus is its high quality blankets and throws which are designed in both classical and contemporary styles, but Magni says that to be successful in the textile industry, you need to keep on top of trends and be ‘forward-thinking’.

“Blankets, rugs and throws have always been the backbone of our production, although we also used to produce woollen fabrics such as tweed overcoats, but those items went out of fashion so we dropped that line. Instead, we expanded on the actual range of blankets; everything from fashion and institutional to tribal.”

“What we really have to do to be successful” explains Magni, “is read the crystal ball and think way ahead of time to predict what is going to be popular and what is going to sell.”

Keeping on top of trends and consumer patterns has allowed the company to explore new product ranges such as microfiber throws which have a superior soft finish, but an old time favourite is Top

Suede which continues to take the market by storm due to its light-weight, luxurious soft suede finish which is available in co-ordinated fashion ranges.

Aranda’s product ranges can be found in many of the country’s leading retailers, “we mainly work with chains who appreciate quality,” explains Magni, “for example Mr Price and Woolworths … after all, Aranda is quality driven.”

“Imports from the Far East, particularly China have resulted in a far tougher industry, mainly because their costs of production are so low…”

THE PRICE IS RIGHT However, being successful in the textile industry isn’t all about fashion trends and consumer buying patterns; pricing is also a very important factor if you want to keep on top of the competition, Magni explains, “Aranda is quality driven to the best of its ability, however we have to be realistic about the fact that we are trading in a viciously competitive industry.

“Imports from the Far East, particularly China have resulted in a far tougher industry, mainly because their

JUL 13 PAGE 69

company report

costs of production are kept artificially low and their

“It’s the difference between a Tata and a Mercedes; if a

government is so bent on creating employment at

customer wants a quality product they buy product B, but

whatever costs.

if they want something cheaper, they buy product A.”

“I hate to say this,” regrets Magni, “but the price in

Magni explains that whilst sourcing quality raw

many instances is more important than the product itself,

materials for a fair price is essential , the company is still

whether or not we like it, it’s a fact, and I don’t think

very focussed on putting money back in to the South

it’s a surprise that the Western world is in the state that

African economy, “when it comes to wool we buy South

it is, also because we have simply exported all of our

African Marino Wool, of which we purchase fairly sizeable

jobs to countries that have flown in the face of all the

quantities.”

achievements that we as a Western culture have fought for for two hundred years; union rights and industry representation etc.”

However, rather than succumb to the imminent threat of cheap labour and production costs, Aranda have developed a range of products for those on a budget to rival its competition.

“Although the majority of our raw materials are high quality products such as wool, acrylic, polyester and cotton, we also produce products that are made from recycled raw materials which we buy at a cheaper price” explains Magni.

PAGE 70 JUL 13

NEW EQUIPMENT In torder to keep producing quality products year on year, it is essential for textile manufacturers to replace certain parts of its production capacity, such as machines.

This can however, be extremely capital intensive.

Aranda has always re-invested each year a portion of

“Although the majority of our raw materials are high quality products such as wool, acrylic, polyester and cotton, we also produce products that are made from recycled raw materials which we buy at a cheaper price”

company report

its plant, and recently have utilized the help awarded by government schemes to keep its production lines efficient and modern.

“Through government’s low-interest schemes, and also the productivity schemes we have bought new plant in the past couple of years and we will carry on utilizing the help as long as the scheme lasts. It is certainly something that is of great assistance and maybe should have been introduced a while ago, but better late than never!” says Magni.

“We all criticise government, and I think rightly so at times, but in this specific instance I think it has been tremendously positive, and we are starting to see some benefits from this.”

Magni concluded by praising the hard work of his colleagues, staff and those involved in the Aranda Learnership College which was established over two PAGE 72 JUL 13

years ago to help disadvantaged individuals further their training in specific areas.

“We train all sorts of people, some from the streets, to further their training in all sorts of applications and industries, and we are happy to report that under trying circumstances we are holding our own; we have good people and we are hopeful that the negative consequences of rapid globalization and the realization of the chaos that is has caused, maybe starting to change.”

.

“…we are happy to report that it is going very well; we have good people and we foresee a very bright future.”

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company report

Shell brings racetrack innovation to the consumer Editorial – Tim Hands Production – Chris Bolderstone The launch of Shell’s latest innovation, its range of V-Power Nitro Plus fuels, has seen both everyday drivers and motoring enthusiasts catered for thanks to the level of performance on offer in this new formulation, developed alongside technological partners Ferrari. Offering a wealth of knowledge and expertise in the field, Shell and its dedicated engineers strive constantly to improve the driving experience across South Africa.

Shell has always been clear as to the main aim behind its operations: shaping the future of energy through innovation. Constantly looking to the future as the energy demands of the planet continue to grow, Shell facilitates worldwide the production of food, fuelling of transport and powering of communication channels.

Now more than ever before, Shell is being called upon to use its famed human ingenuity, innovation and technology in order to grow and develop in line with the ever-expanding world population, while ensuring its innovative operations impact to the least degree possible on the environment, both in South Africa and across the world.

It has not only been the continued growth of the global population that has placed such pressure on Shell to come up with ways to ensure a bright energy future,

PAGE 74 JUL 13

but equally crucially the number of people moving from poverty into ways of life that now require the usage of modern energy.

Central to Shell’s ability to meet this demand is a continued focus on finding new sources of energy, whilst simultaneously making the most and best use of existing gas and oil resources. As the cleanest-burning fossil fuel, Shell has gone to great lengths to open up new resources of natural gas, having spent now more than 35 years developing technology to convert the extracted gas into liquid products used for heating fuel, transport fuel and lubricants.

In a similar vein, Shell’s boundless explorations have seen it able to profit from the vast resources of oil and natural gas to be found in the Arctic. Again this has required a combination of Shell’s work both past and present: the extensive knowledge it has gained from

Shell South Africa

its decades of experience working in such conditions combines with the advanced technologies at its disposal in order to help balance economic, environmental and social challenges encountered along the way.

One of the most exciting products of Shell’s commitment to innovation and progress, and perhaps thankfully not requiring a trip to the Arctic to see it in action, is its new V-Power Nitro Plus fuel. Shell bills its newest product as the latest generation of Unleaded and Diesel performance fuels, which have been designed to reinvent the way fuels work on a car’s engine. This line of fuels promises an immediate impact on the performance of the car, working on deposits which can hamper its performance the instant the fuel hits the engine.

Once again, this is a product that results from the collective weight of Shell’s extensive experience in fuels innovation - more than 100 years of it, in fact, with its

first branded gasoline petrol ‘Shell Spirit’ having been launched in 1907.

Nowadays this experience is continually built upon by Shell’s team of around 120 fuels scientists and specialists, whose work enables exactly the sort of innovation on show in the V-Power Nitro Plus fuels. It is in part through these specialists that Shell is able to commit to investing more than 21,000 hours into development and research each year, and at the very highest level of motoring expertise; the technology that makes its way onto the road in the form of such products as the Nitro Plus fuels is a direct result of Shell’s working with Scuderia Ferrari in Formula One. Indeed, the Shell V-Power Nitro Plus Unleaded contains 99% of the same types of compounds found in the Shell V-Power race fuel powering the Scuderia Ferrari through the 2013 FIA Formula One World Championship. ...continues on page 78 JUL 13 PAGE 75

Companies today realise that to remain competitive they need to streamline their business and organisational processes in order to concentrate on their core activities.

The trend to outsource offsite archive storage has been one of the biggest fundamental changes in the business process in the last decade.

The Document Warehouse understands this and provides our customers the offsite document storage solution and various space-saving filing solutions and records management software for tracking their files onsite or offsite.

In a broader sense The Document Warehouse (TDW) offers warehousing space to store documents. In a narrower sense, offsite document storage includes services such as indexing, packaging, transportation, storage, retrieval of documents, scanning and mailroom services.

There are additional services such as onsite management of documents, providing the software to assist in the process and also providing staff. In addition, TDW offer training and consulting services to organisations.

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THE DOCUMENT WAREHOUSE

The art of filing From creation to destruction, The Document Warehouse can handle all of your record management needs and train you to effectively manage your own filing to make your business that little bit easier to govern.

By Joe Forshaw

Everyone knows the hassle that comes from filing and organising company documents and paperwork; days and weeks can be spent trying to make sense of unorganised piles of receipts, tax forms, certificates and other necessary documents. The Document Warehouse is a company that can help with this problem. They realise the importance of good records management and are experts when it comes to handling company records and training businesses on how to more effectively deal with their documents.

The Document Warehouse business began in 2000 as an offsite document storage and record management company in Johannesburg. Since then it has grown tremendously now with branches throughout Southern Africa and Australia, England, Ghana, Botswana and more opening soon. It also has a highly rated and accredited training programme in records management. Since the exception of the training programme in 2000 more than 5000 delegates have been trained. Virginia Hendricks, training and consultant manager, explains.

“The training programme is specific to filing, records management, disposal and the archiving of records. Anybody in any organisation can be trained to set up a filing system where records can be found quickly and easily. Private and public sector individuals are constantly being trained.

The training will not only equip delegates to manage their own organisation records but they will understand why it

is important to keep records according to the Acts. In fact everything you need to know about filing will be explained including how to develop a classification system for an organisation so that they can retrieve documents quickly and easily.”

The Document Warehouse trains people on how to manage records right from creation through to disposal. A large percentage of their customers come from the public sector but there is strong customer base in the private sector, something which they are looking to grow.

“We are fully accredited with the Services SETA (Sector Education and Training Authority) and SAQA (South African Qualifications Authority). Learners receive a certificate of competence on successful completion of portfolios of evidence.

We are constantly developing further courses in disposal, mailroom management, policy design and other areas,” says Hendricks.

The Document Warehouse is passionate about records management and it is because of effective practices that we understand the history of our companies and our country.

There is also a large amount of legislation that forces the storage of some documents. “The new companies act says you have to keep financial records for a minimum of seven years,” says Hendricks, An effective record management system can streamline your business and eliminate extra work arising from inadequate filing. The Document Warehouse can help you develop and maintain a system – vital in any modern business. ●

“The training programme is specific to filing, records management, disposal and the archiving of records”

AUG JUL 12 13 PAGE PAGE 29 77

company report

...continued from page 75 It is the Shell V-Power Nitro Plus Unleaded which receives top billing from the company, having been developed by Shell scientists alongside its technical partners Ferrari, with its months of extensive testing having brought about, in Shell’s own eyes, its ‘best performance fuel’. It is no wonder that this fuel is Ferrari’s own choice for improved performance in its own cars, in no small part due to the high content of friction modifier - 25% higher than previously - which is designed to reduce friction in critical engine areas, a crucial factor in helping to deliver more power to the wheels.

This Friction Modification Technology is a perfect example of Shell’s partnership with Ferrari providing an ideal ‘test bed’ for the development of new technologies, and an environment to test new fuels in extreme conditions. Because Shell scientists and engineers work on both types of engines, they are attuned to the similarities and differences and can then apply the same technical insights for optimal results, making so smooth this ‘track to road’ transfer.

The benefits of Shell V-Power Nitro Plus Unleaded do not stop at this reduction of friction between the

PAGE 78 JUL 13

piston assembly and cylinder wall. Its special additives also help stop performance-robbing deposits from building up around the intake valves and fuel injectors, allowing these to remain much cleaner than before.

“Our commitment to performance extends from the race track to our forecourts”and it is important to survive” Shell V-Power Nitro+ Diesel represents Shell’s new and improved diesel formulation and, despite coming with a slightly quieter fanfare, boasts a host of upgrades to its previous incarnations. Again, this primarily concerns the fuel injection systems, this time containing a vastly more powerful detergent to provide a much more fast and effective clean-up of these systems. As a result, this also means that the latest diesel engines are offered a far better level of protection than could have been expected with previous formulations of Shell V-Power. The question of maintaining power is also addressed by the Diesel version of Shell’s latest fuel, while its anti-rust functionality helps prevent corrosion

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of precision-engineered fuel injection systems.

Durban will play host this year to the Top Gear Festival at the Moses Mabhida Stadium, running from 15 to 16 June. It is the ideal venue for the festival, given that approximately 25% of Shell’s service stations are found in KwaZulu-Natal, and a fitting partner for Shell South Africa with its wealth of motoring expertise, who has announced its continued sponsorship of the event, and with good reason.

It is the perfect platform for visitors to view the premium Shell V-Power fuel’s performance promise in action, showcasing the innovation in a bid to build yet further on the success of last year’s event. Shell’s continued and growing involvement is perhaps best summed up by Retail Marketing Manager Debbie Foley, “People who are passionate about their cars and all things related to motoring attend the Top Gear Festival and we absolutely share this passion.”

Once again, Shell demonstrates its dedication to erasing that line between the track and the road, making this product as much for the casual motorist as for the dedicated racing enthusiasts who will be in attendance.

Foley points out just how much of its performance

characteristics the fuel retains in its forecourt form, “The Shell V-Power race fuel and road fuels are so similar that you could fill up a Scuderia Ferrari Formula One™ car with the formula we sell at our service stations. Our commitment to performance extends from the race track to our forecourts.”

“People who are passionate about their cars and all things related to motoring attend the Top Gear Festival and we absolutely share this passion” With the range of attractions also having been extended since last year, and ranging from Shell’s Pit stop tyre changing challenge, a remote control car track, and even a racing simulator for an accurate representation of the challenges of a Formula One car, clearly there is a strong focus on fun and a light-hearted appreciation of the joys of motoring. However, Shell ensures, crucially, that the more serious drivers are also handsomely catered

JUL 13 PAGE 79

company report for, offering visitors an opportunity to explore Shell apps, and learn more about Shell’s products and services.

Shell is also perfectly placed to offer some sage advice to motorists across South Africa, striving to improve performance on the road via its advanced driving tips.

Although we would all love to consider ourselves experts on this subject above most others, in reality there is always a particularly clever tip to be picked up from someone with Shell’s weight of experience. These are centred around safety on the road and driving efficiency, with, for example, the acceleration sense section providing reminders of some crucial disciplines. Others are far more revelatory, and arguably more important for the majority of motorists. The importance of tread depth is often overlooked, but Shell’s research demonstrates why it should be at the forefront of our minds - tyres with a 3mm tread have a 25% better performance than those at the legal minimum of 1.6mm. When translated to stopping distance this represents an extra eight metres, or 25 feet, in wet conditions.

Shell is striving tirelessly to bridge that gap between passionate drivers and casual motorists, in part through the innovative racetrack-ready fuels now available, but also with a constant focus on educating and developing the automotive knowledge of South Africans across the country.

.

PAGE 80 JUL 13

G4S is a proud security service provider to Shell.

G4S is the world’s leading International security solutions group, operating in 30 countries on the African continent, providing a diverse range of services, including world-class Cash solutions, manned guarding and technology.

Our products and services add value to 58,000 customers in Africa. Applying our expertise and knowledge derived from providing security solutions in diverse environments in more than 125 countries around the world, we turn our customers’ challenges into opportunities.

Our Services include: Manned Guarding Services: G4S provides professional, trained and qualified security personnel to a diverse crosssection of industries, with a strong foothold in the oil & gas sector.

Journey Management & Close Protection: Services are delivered by fully accredited skilled personnel and include meet-and-greet services, airside protocol, route reconnaissance, secure transportation & executive home security.

Technology: G4S has a range of leading edge products developed in-house, such as CCTV, intruder detection, time & access management, biometrics, security management systems & mobile camera solutions.

National Control Centre (NCC): Current capabilities include monitoring of alarms & CCTV, crime intelligence gathering & analysis, remote off-site monitoring (ROM) & vehicle tracking.

Cash Solutions: We provide true end-to-end solutions which include in-store technology, cash cycle software, cash transportation services, monitoring & maintenance of hardware / software.

G4S is the only private security company in Africa that has ever been awarded a Top Employer certification.

For more information on G4S, visit www.g4s.co.za Shell.indd 1

7/1/2013 9:33:33 AM

company report

Wild and Marr: loud and proud Editorial – Lauren Grey Production – John Cliff

The South African general election of 1994 was a catalyst for huge transformation in the country; not only did it mark the end of the apartheid but it allowed for exponential growth within the country’s trade and commerce. Gustav Teitge, Systems Engineer at Wild and Marr explains how the election opened up new opportunities for the audio distributor and contributed towards its success.

As Southern Africa’s renowned fore-runner in the distribution and installation of professional audio and video equipment, Wild and Marr has gone through many changes since its inception, and on the eve of its 70th anniversary, Systems Engineer, Gustav Teitge explains where the company first began.

“Originally the company was founded with a view to marketing army surplus electronic components.

“In the early days we used to sell a lot of electronic components, and then we ventured into valves and loud speakers,” says Teitge, “Joe Copans, the current Managing Director, eventually decided to transform the whole company and moved it towards the professional audio industry. The very first brands he secured were Shure and JBL Professional.”

JBL manufactured loudspeakers for a number of

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years and was arguably the most respected loudspeaker producer in world markets.

Originally founded by James Bullough Lansing (JBL), the company was acquired by the Harman group with Sidney Harman being the CEO of this group.

Harman’s wife was a US Senator and Harman himself was a staunch anti-apartheid lobbyist.

Notwithstanding the fact that JBL had become an iconic product globally, it was unavailable to the South African market as Harman personally imposed a sanction on the distribution of JBL in South Africa.

Copans was able to secure the sole distribution of JBL in South Africa with the onset of a democratic South Africa.

The distribution of Shure too, became available shortly after South Africa became democratic in 1994 and Wild and Marr was able to secure the distribution of

Wild and Marr

this product range as well.

Shure obviously proved to be a highly complementary product to JBL and together these two products enabled Wild and Marr to attain a meaningful market share in the Pro Audio market in South Africa.

Simultaneously with Wild and Marr’s entrance into the pro audio market, Harman acquired a number of highly respected brands in the Pro Audio industry.

“The brands in the Harman Professional Group were individual brands at the time, before the group bought them all and put them under one umbrella. Luckily, we already stocked the majority of the brands they acquired and so Harman decided on Wild and Marr to be a fitting partner” says Teitge.

“The range includes JBL, Soundcraft, BSS, DBX, Lexicon, Crown and Shure as well as a number of peripheral products such as Tascam, Neutrik Connectors

and Klotz Cable.

“Shure also acquired DIS Delegate Systems and Wild and Marr is proud to announce the fact that is today the distributor of the DIS as well.”

In addition to the above Wild and Marr also distributes Clearone, a high quality echo cancellation product for the video conferencing (VC). Clearone has also entered the VC market and Wild and Marr is able to offer VC market solutions as well.

The company’s diverse product range, and its ability to service a wide range of market segments, has enabled Wild and Marr to negate the effects of the global recession extremely successfully.

PRODUCT RANGE With its extensive product range, Wild and Marr are renowned specialists in custom audio engineering,

JUL 13 PAGE 83

company report audio/video integration, computer aided design and acoustic analysis, boasting some of the industry’s biggest named brands.

“We have such a huge product portfolio that last year we hosted our own mini expo and rented out a conference facility,” says Teitge. “We kitted out the entire expo with our products, which gives you an idea of how extensive our product range is!”

Wild and Marr’s products have received industry recognition for their superior quality since the company’s early beginning. JBL and Shure have received awards for their design and outstanding performance over the years.

Shure’s ULX-D Digital Wireless won the Best Wireless System of the Year Award 2013 and its SM9HS, the Best Cabled Microphone of the Year at the Music and Sound Retailer 27th Annual Music and Sound Awards 2013.

ULX-D was also a winner in the Wireless Microphone Systems Category at the Pro Audio Review Excellence Awards 2013. Shure’s other brands which won awards were the X2, KSM 9HS and PSM 1000.

JBL Professional also announced during the month of February 2013 that its VTX Series line array loudspeakers won the 2012 Good Design Award from the Chicago Athenaeum: Museum of Architecture and Design and the European Centre for Architecture Art Design and Urban Studies.

AFTERSALES SERVICE Not only does Wild and Marr pride itself on the actual range and performance of its products, but also on

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the industry expertise of its staff and unrivalled aftersales service.

“We have in excess of 90 employees in South Africa; our main branch is in Johannesburg which is our main distribution outlet. We have two more branches; one in Cape Town and one in Durban” explains Teitge.

“Not only do we distribute some of the industry’s leading brands, but we ensure we offer unrivalled engineering skills and aftersales support. The aftersales service and support is indeed a major catalyst to our future success,” he says.

Away from the ability to supply a diverse range of world class products, Wild and Marr believes that it will continue to succeed if it is committed to customer relationships, coupled with professional aftersales service and support. To this end the company invests substantially in training and boasts an efficient and very effective service department.

EXPANSION PLANS With an award winning portfolio of products and industry expertise, it is no surprise that Wild and Marr are looking to expand further into niche markets as Teitge explains, “One of the current expansion projects is in the broadcast market.

“As broadcast is essentially a niche market, and Wild and Marr’s product offering in this market were limited, the company had previously chosen not to enter this market.”

Recently, Wild and Marr has been able to gain access to a number of specific broadcast products, and in so doing, is now aggressively attacking this previously untapped territory.

“One of the aspects which makes our company strong is that we’re not just involved in one aspect of the audio market; I am very proud to say we are involved in all sectors of the audio industry starting from the lowest public address or music industry market and working our way through the different markets such as professional audio, corporate audio and broadcast to name a few,” concludes Teitge.

.

For Performance, Perfection and People.

High-end accessories Innovative products First class materials Excellent workmanship Made in Germany

“One of the current expansion projects is in the broadcast market”

www.k-m.de Distributor: Wild & Marr (Pty) Ltd

Isando Business Park · Unit E3, Gewel Street Isando, 1609 Johannesburg - South Africa

JUL 13 PAGE 85

company report

State-of-the-art steel solutions Editorial – Joe Forshaw Production – Hal Hutchison

Remkor Technologies is one of the country’s premier steel manufacturing businesses. Founded in 1981 by Nino La Monica, the company is now run by Nino’s son and current MD, Rafaelle. He tells IndustrySA that steel prices and exchange rates have caused problems but overall, the company is looking to expand both its footprint and product range.

After the fire disaster that caused untold disruption at the ArcelorMittal plant in Vanderbijlpark back in February, companies that work in steel manufacturing felt the effects of the downturn in production. The Vanderbijlpark works is one of the world’s largest inland steel mills and the largest supplier of flat steel products in sub-Saharan Africa. When the plant was shut down following the fire, steel had to be sourced from elsewhere and companies turned to imports, from places like Brazil and Malaysia, to fill the void left by ArcelorMittal, the world’s largest steel producer.

Obviously, with supply levels down, prices shot up and this became problematic for all companies who deal with steel. One company in particular who felt the effects is Remkor Technologies, a Johannesburg

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based steel manufacturer. Managing Director, Rafaelle La Monica, tells IndustrySA that although steel prices have caused concerns, the business is looking at new product lines and new markets to continue the fantastic growth that has been realised over the last three decades.

“We had a big problem in February with the price of steel. We rely on ArcelorMittal and in February there was a problem at their plant and this resulted in huge problems for us getting material to the market place.

People resorted to imports to fill the void and this pushed the prices up and since January/February they have not come down,” he says.

EXPONENTIAL GROWTH Remkor started out as a small, one man concern,

Remkor Technologies

making tools for the automotive industry. Today the company is home to over 170 employees and occupies 20,000m² of land on two adjacent stands with offices and factories totalling 8500m².

Since its establishment, the company has moved on from tool manufacturing and now services a range of industries as La Monica explains: “We are now much more diversified, we work in just about every industry there is, as long as there is a requirement for steel.”

The Remkor factory in West Turfontein has stateof-the-art capabilities that have vastly been developed over the years. The capabilities of the factory currently include laser cutting, tool and die manufacture, punching, press brakes, welding, brushing machines, powder coating, finishing and assembly, and numerous CAD systems that link all the CNC processes together.

“My father was the owner and founder of the business,” says La Monica. “We started in 1981 so we have been going for 32 years. We began as a small tool and die making business for the automotive industry, from there it evolved into production for the whole automotive industry and we’ve carried on growing so now that tool making is very small part of the company.

“The main industries we service are the telecoms, domestic appliance, public seating and metal enclosure industries. In the appliance industry we do a lot of decorative cooker hoods, domestic cooker hoods and stainless steel fittings.

“My father came directly from Italy, he had a trade there as a tool maker. He worked in a few companies locally before going into a partnership and eventually becoming the sole owner.”

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company report

“We are continuously investing in the business and people understand that we are here to stay” Remkor had particularly strong dealings in the telecoms industry, manufacturing booths for public telephones, and this contributed greatly to the industry leading reputation that has been built up over the years.

However, the rise of the cell phone industry has all but killed off that part of Remkor’s business and impacted on their exports as well.

“We did very well in the telecoms industry, manufacturing telephone booths,” says La Monica. “At the moment, that is a dyeing business and is now basically non-existent. We do still keep items in our product range as we do still get a call for things from time to time in African markets but this is not a growth area.

“In the years that we were able to manufacture, we did very well locally and we exported products to about 18 countries throughout Africa and the Middle East.

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“Cell phones have taken over what we were doing at that point in time. The payphone business is very capitally intensive. It takes a lot of money just to start the process with infrastructure. Buying the booth, the phone and implementing the backbone is very expensive and nobody wants to do that anymore. Everybody uses a cell phone these days so payphones have gone out of the mainstream.”

The last big project that Remkor had with public phones was four years ago and because of the decline in activity in that market, new opportunities are now being sought with one area of focus being the clean energy market as La Monica explains: “Payphones are often stuck in rural areas and operators have to maintain them so they are not overly popular now,” he says. “The last of our big projects was with Vodafone in Ghana and that was in 2009 but only because they were required by law to

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implement a public phone system.

“We are in phase right now where we pushing new products and getting into new fields. There is a very big drive towards clean energy and there are a lot of initiatives going on which may encourage us to change our focus but still staying in the sheet metal manufacturing environment.

“We have experience with solar power. We have been making telephone booths with solar panels on top for the last ten years. We’ve also done street signage which incorporates solar panels. That is the sort of market where we could have an impact rather than power generation.”

If Remkor can combine its experience and business acumen with the successful exploitation of these new opportunities then it is likely that the company could go on to achieve further success, the likes of which it saw in 2008.

THE PEAK OF 2008 “We had the best year ever in 2008” says La Monica “because locally we had a big drive with infrastructure surrounding the World Cup. We supplied a lot of

Handles

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components for the construction of the Moses Mabhida Stadium in Durban. We also supplied components for the Nelson Mandela Bay Stadium in Port Elizabeth and we also did work with the Gautrain. This resulted in a great year in 2008.”

It may have been Remkor’s ability to produce large, complex orders for customers with quick turnaround times that gained them these significant contracts but it was more likely the company’s meticulous focus on quality. This is something that has seen the company become the preferred supplier in its chosen sectors and regularly produce superior products and service.

The focus on quality and the inward investment from the management are further indicators to external and internal stakeholders that the company has a long-term plan and the fact that Remkor operates to international quality standards, brings about further opportunities with the potential for exporting.

“A lot of people see the commitment from our family and realise there is a long term vision for the business,” says La Monica. “We are not just shareholders who are here to make a buck and leave. We are continuously investing in the business and people understand that we

JUL 13 PAGE 89

company report

are here to stay so the result is people stay with us for a long time.

“We are audited by a German company and we pass all our audits with very little comment and very little problem and it’s been like that since we started. The environment we present, the facilities we have and the commitment we offer make it clear that this is a business that is taken care of.”

Although the company is fully equipped and experienced with regards to the exports of products, the export market itself has been a difficult environment to operate in because of the widely publicised instabilities with the currency exchange rates. However, with the slightly improving rates, the market for exports may

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be an area in which Remkor could look to for future growth.

“At the moment, 95% of our business or more is local in South Africa” says La Monica. “Exports have declined because our product was not a growth product, especially overseas, and we have also had problems with the exchange rates. The currency strengthened significantly in 2009 and that made exports difficult with local costs. More recently it has weakened and started to open doors and multi-nationals have started to ask questions regarding whether it would be worth manufacturing locally again so it is possible that we could export in the not too distant future.”

With 32 years of expertise behind it, Remkor has the

Remkor Technologies perfect platform to achieve long-term growth and its vision of becoming the most sought after, internationally recognised, superior supplier of engineered products in Southern Africa.

Having previously completed work for clients in countries including the UK, Argentina, Chile, Qatar, Oman, Zimbabwe, Ghana, Sudan, Angola, Liberia, Uganda, Nigeria, Madagascar, Mauritius, Namibia, Botswana, Lesotho, Swaziland, Zambia, Rwanda, Kenya and Mozambique, Remkor has vast experience of working in new markets but La Monica concludes by saying that, for now, sub-Saharan Africa is the realistic target for expansion.

“The growth story for most South African companies is into the African market. That is where we see the biggest potential. Markets like Europe and North America are a bit difficult at the moment. Sub-Saharan Africa is where the potential lies.”

.

“Sub-Saharan Africa is where the potential lies”

As a leader in the international transport market, JAS Forwarding maintains a constant focus on innovation and total commitment to its own philosophy: the product must be delivered securely and on time.

Jas Forwarding S.A. (Pty) Ltd 2 Longclaw Drive (Cnr. Koeberg Rd) Montague Industrial Estate Montague Gardens Cape Town 7441 Tel: +27 (0) 21 527 6000 Fax: +27 (0) 21 527 6098 www.jassouthafrica.com lvaneck@jassouthafrica.com

JAS Forwarding S.A. (Pty) Ltd, JAS Projects Division 65 Maple Street , Pomona Kempton Park, 1619 Tel : + 27 11 387 9600 Fax: + 27 11 387 9665 www.jassouthafrica.com mpillay@jassouthafrica.com

JAS Forwarding S.A. (Pty) Ltd Johannesburg (HeadOffice) Tel: 08600JASSA (52772) +27 (011) 387-9600 (Switchboard) E-mail: jnb-sales@jassouthafrica.com

company report

Design Build Insure Editorial – Roland Douglas Production – John Cliff Twintec is the quality, market leader in the industrial flooring sector. The company offers a complete in-house service from initial design to full build and final insurance and guarantee. Projects Director, Martin Kerrigan, tells IndustrySA that there is more to a perfect floor than just good concrete.

As we discussed in last month’s edition, industrial logistics is becoming more and more important in South Africa and as the rise of consumerism continues, companies are adjusting their focus and placing a bigger emphasis on supply chain activities to ensure that goods are delivered to the right places, at the right time, with as little fuss and unnecessary cost as possible.

We have seen distribution centres pop up around the country with the likes of Shoprite, Massmart and Clicks investing heavily in their warehousing capabilities but one of the issues that often goes unnoticed and regularly gets overlooked is that of the floor - that all important concern that can quite easily fall to the wayside and ‘look after itself’.

One company who is now recognised as the market leader when it comes to quality industrial flooring is Twintec, formed in the mid-90s and established in South

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Africa in 2010, Twintec now employs over 350 people, has offices in 19 countries and turns over €150 million each year.

The South African division of Twintec is headed

by Projects Director, Martin Kerrigan, who tells IndustrySA that although the market for specialist industrial flooring is competitive, Twintec’s innovative approach makes them the unrivalled industry leader.

“In terms of quality, without a doubt we are the frontrunner. In South Africa, we set the standard in terms of design, quality and production. At this stage, there are some interesting opposition. There are attempts to copy what we do but it has proven not to be as easy as we make it look sometimes. It’s not something you can pick up overnight; there is a lot of design, technology and invaluable experience involved.”

What makes Twintec floors so popular is their high quality, long-lasting durability, innovative make-up and

Twintec South Africa

client aftercare. The company’s floors are predominantly made up from concrete with undulated steel fibres. The highly resistant AFT fibre (advanced fibre technology) is characterised by its shape and allows a perfect reinforcement of concrete. Extensive independent testing has confirmed that the undulated shape and integration technology are key factors leading to optimal design performance.

“One of the machines we have developed is a fibre integrator or ‘blast machine’. We use this to blast the steel fibres into the concrete and this helps us to maintain a very quick production rate without compromise of quality at the same time,” says Kerrigan.

FROM THE GROUND UP The company’s birth in South Africa, unusually, came about through a chance rendezvous after a Shoprite engineer noticed the class of Twintec’s work on a site in

the Middle East. Kerrigan, though initially from a chemical engineering background, has focussed on specialist concrete flooring throughout the globe for close to 30 years and was offered the position at the helm of the company in South Africa and Twintec’s drive into Africa began.

“We went to South Africa in 2010 with Shoprite” says Kerrigan. “They had seen us on site in Saudi Arabia and they liked what they saw so they asked if we could do the same for them. We seized the opportunity and that’s how we got kicked off in South Africa.

“The standard and design in South Africa was very basic for modern warehousing. Our product is very different.

“Shoprite have very big distribution centres. They had multiple problems with joints and constant repairs. Our design removed the issues that they were having and vastly improved there operational efficiency.”

While Twintec have a variety of products available, one

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of the most popular is the Freeplan Jointless SFRC (steel fibre reinforced concrete) floor range. This allows for large floor areas to be cast with no induced joints.

“What we specialise in is the ability to put down large areas of flooring, commonly in excess of 500 cubic meters of concrete or 60-70 truckloads of concrete. In South Africa, we find that our optimal daily output is about 2,400m2 per day comprised of two large panels having between 30m and 50m intervals between joints. That’s at least 85% less linear metres of joints to have issues with! ” says Kerrigan.

Using steel fibres to strengthen concrete is not a new phenomenon and research into the capabilities of steel fibres goes back a long way as Kerrigan explains: “The basics go back to the development of steel fibres.

The theory of reinforcing concrete with steel fibres is very old, some patents date back to 1912 in New York. A big development was taking the joints out of the very large panels. In 1997, we specialised in steel fibres and what could be done with those and there are many applications for this. Our products modify the structural properties of concrete rather than simply reinforcing its inherently brittle nature.”

Twintec works with established international educational institutions to continue to understand the capabilities of steel fibres and concrete.

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“The research and development with steel fibres is on-going,” says Kerrigan. “We work with the University of Sheffield in the UK and they underline the performance of our steel fibres and our methods. If you’re doing this on an industrial scale the method that you use is important; it’s one thing doing something in a laboratory but it’s another being able to do it on an industrial scale, every day and then being able to replicate those results.”

MASS PROJECTS In January, Twintec completed a 31,300m² jointless SFRC floor slab for Massbuild’s new RDC (Regional Distribution Centre) in Midrand. The facility, which opened in April 2013, was based on similar facilities in the USA and for Twintec the project was a success, adding another big name client to the portfolio.

“When they were looking at building this fairly sizeable distribution centre, of around 31,000m², they wanted to look at the long-term running costs so they decided to invest in the floor rather than just going with the cheapest option and accepting the likely consequences and associated costs,” says Kerrigan.

“Price is always important but quality is paramount”

Twintec South Africa He points out that your floor is a long-term investment, an investment which can have dramatic effects of the operating costs of your business. The proof of this has been experienced by Shoprite, as Kerrigan explains: “The performance return and the reduced cost of maintenance, not only of the floor but of mechanical handling equipment, offers major improvements and this is the sort of thing that Shoprite have already seen. Their operational efficiency on our floors is far greater than the traditional floors that they have. They have reduced the cost of maintenance on their trucks and the floor becomes a minimal-issue to them.”

Obviously, Twintec incurs considerable costs dealing with the amount of concrete and other raw materials that make up its products and Kerrigan suggests that although price is an issue, the main focus for the company is ensuring longlasting quality.

“Price is always important but quality is paramount,” he says. “It’s the main driver; you’ve got to be able to confidently underline the long-term durability of the product for many years to come. Not only does it have to look nice on day one but year ten is very important as well so we take pride in our long list of satisfied repeat

clients. The quality of the concrete is a large factor in that.

We work with the best local suppliers; initially with their technical departments to produce our very exacting concrete specification and during production to check and maintain a range of real-time performance tests, beyond normal basic QC requirements to control and maximise the finished floor quality and durability. It’s who can supply the right quality with the rate of production, in the area that we are working.”

EXPERIENCE & KNOW HOW One of the most recent developments at Twintec South Africa, came about in May when the company formed a strategic partnership with Llevell Laser Floors (LLF). The partnership will see the two companies work together on the design and construction of industrial concrete flooring throughout South Africa.

Kerrigan tells us that one of the most vital components in the Twintec business is experienced employees. In this respect Twintec, utilise their experienced international artisans in combination with its small full-time local staff and partner, Levell Laser Floors.

“We have entered the early days of a joint venture with LLF to synergise the combined strengths of our companies

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and long-term successful experience. For Twintec products, we will maintain entire control of all the core processes throughout, from start to finish, from concept and design through to the finished article and our professional Indemnity. LLF’s local knowledge and experience is very welcome and together I’m sure we’re going to define the market expectation for quality logistics floors in South Africa” he says.

“We keep a small local staff who look after all the administration, sales, production management and aftercare.

In terms of skilled labour, up until now we have always imported skilled labour because of their understanding of being able to produce quality in such a large scale. Our output is twice as much as the nearest opposition each day.

We need to always improve and maintain those standards and that requires people who have long-term knowledge and experience. We look forward to sharing our knowledge with LLF and to learning from them as well!”

“A 10,000m² job will only keep us busy on site for around a week so it makes no sense flying guys in for a job like that, it’s just not sustainable. In the long-term we are committed to the development of a highly skilled local workforce with minimal reliance on overseas personnel.”

GROWTH & EXPANSION As mentioned above, Twintec is active around the world and has a significant pipeline of projects. In Africa, the company is looking to grow its presence and become recognised as the industry leader in not only South Africa, but in all of the southern African nations. However, the company will not just take any project to speed up its

PAGE 96 JUL 13

expansion, each project is carefully selected.

“We’re looking at projects over the border in sub-Saharan Africa” explains Kerrigan. “We are looking at projects in Mozambique and Namibia, but only the right projects. It will be a change of standard for those regions with the right client. This is about investing in your floor, if you’re looking for the cheapest possible rate, you’ll never get us. We’re not here to redraw the bottom line; we’re here to offer the best possible quality at the cost that entails.”

It is refreshing to hear that a company is actively looking to expand and grow in what is difficult time for the business community following the global economic slowdown.

Kerrigan concludes by saying that the market for industrial logistics is steady in these turbulent times and with big name clients always looking for expansion, Twintec will be able to grow and achieve its vision of ‘becoming the specialist contractor of choice by providing a quality product and therefore optimising floor performance and minimising maintenance problems for clients through innovation in concrete floor design and production and maximising performance.’

“The industrial logistics sector is going fairly well, it’s steady, not on a rampage but there is a stable flow of projects.

Companies are investing in developing their logistics operations. Shoprite for example, are always investing in new logistics centres so our sector is comfortable.”

.

“In South Africa, we set the standard in terms of design, quality and production”

INDUSTRY RECOMMENDED

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

AUDIO EQUIPMENT KÖNIG AND MEYER German manufacturer of music stands, microphone and instrument stands, speaker stands, seats and accessories for lighting, sound and studio technology +49 9342 8060 www.k-m.de WILD AND MARR Southern Africa’s renowned fore-runner in the distribution and installation of professional audio and video equipment +27 11 974 0633 www.wildandmarr.co.za BROKERS JIVAN & JIVAN Short term insurance brokers +27 31 573 1390 www.jivanandjivan.co.za CONCRETE SIKA Manufacturers of ViscoCrete, a technology which brings several innovative options to concrete mix design, such as the capability to substantially reduce the water content of a mix +27 31 792 6500 www.zaf.sikha.com CONSUMER MANUFACTURING BLISS CHEMICALS The company behind the MAQ washing powder brand +27 11 474 2626 www.blisschem.com

PAGE 98 FEB 98 JUL 13 13

ENERGY DAVI Italian manufacturers of wind tower components +39 547 319611 www.davi.com

SHELL SA Global group of energy and petrochemical companies +27 11 996 7000 www.shell.com ENGINEERING BOLT & ENGINEERING DISTRIBUTORS GROUP The Bolt & Engineering Distributors Group (B.E.D.) has been supplying the construction and mining industry with quality tools and fasteners since 1983 +27 11 824 7500 www.bolteng.co.za

CNC CLEAR CUT Leading South African precision engineering firm supplying complete affordable CNC Plasma Cutting Solutions +27 12 541 0552 www.cncclearcut.co.za CONFERHEUR ENGINEERING Service both the private and public sector with the manufacturing of everyday parts and components +27 21 862 1000 GRW Design and manufacture superior road tankers for the bulk transport market and

provide essential maintenance and repair services +27 23 348 6300 www.grw.co.za JOHN BEAN TECHNOLOGIES Suppliers of tank truck metering, sealed parcel delivery systems, tank truck fittings and terminal measurement solutions +27 21 982 1130 www.fmctechnologies.com FREIGHT JAS FORWARDING International freight forwarding company +27 21 527 6000 www.jas.com PLASTI-CO Specialising in forwarding and clearing +27 11 391 7777 www.plasti-co.co.za HYGEINE SOLUTIONS STEINER HYGEINE Service-orientated organisation providing innovative hygiene solutions to a wide spectrum of businesses and institutions across all industries throughout South Africa +27 11 923 9490 www.steiner.co.za INDUSTRIAL FASTENERS ASTRA FASTENERS Distributors of industrial fasteners for the automotive, rail and aviation sections as well as a general range of

INDUSTRY RECOMMENDED

fasteners +27 11 918 6696 www.astrafasteners.co.za INDUSTRIAL FLOORING TWINTEC SOUTH AFRICA Part of the global Twintec Group of companies; Industrial flooring ‘jointless’ steel fibre reinforced concrete floor slab specialists +27 21 914 7752 www.twintec.co.za

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

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