Ec industrial & business news issue 62 by The Media & Events Company

EASTERN CAPE INDUSTRIAL & BUSINESS NEWS

YOUR LINK TO INDUSTRY THROUGHOUT THE EASTERN CAPE

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July / August 2014

Inside Jeffreys Bay wind farm inauguration - page 3

Materials Handling, Bulk Handling & Logistics - page 7

Focus on Automotive - page 13 Plastics & Rubber page 16

Water & Effluent Management - page 17 COEGA Industrial Development Zone page 21

Company & Product News - page 23

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issue no. 62

Business visa bonus for Eastern Cape’s IDZs

ome Affairs Minister Malusi Gigaba (pictured) has gazetted a list of sectors where the capitalisation requirements for a Business Visa will be reduced or waived, including a number that are major areas of focus for the Coega and East London industrial development zones (IDZs). In terms of a separate notice, Gigaba has set R5 million as the financial or capital contribution that must be invested in an established business or one that must still be

established in respect of a Business Visa and Permanent Residence Permit. The funds must originate from outside South Africa and the capital contribution must be new machinery or equipment. Among the sectors listed by Gigaba after consultation with Trade and Industry Minister Rob Davies is agro-processing, which includes aquaculture and biofuels both of which are areas of focus for the two

IDZs and where they have already secured investment. Another sector where the Eastern Cape has a specific interest is renewable energy that includes onshore wind power - the manufacture of turbines and blades - and solar PV. Significantly an area that is also included and that could benefit the province and specifically Nelson Mandela Bay is the Nuclear Build Programme, which includes joint ventures, consortiums and the establishment of new companies “to grow South Africa’s nuclear manufacturing capacity and nuclear sup-

ply industry to supply into the nuclear build programme”. Also included are automotives and components along the whole value chain and also the business process outsourcing sector which is an area of focus for the Coega IDZ. The ministers have collectively also included the oil and gas sectors that includes the exploration for shale gas as well as offshore oil and gas; maintenance in terms of ship and rig repair and the infrastructure for oil and gas-to-liquid refineries.

Enquiry No: 1

Coega investor construction booms

HE Coega Development Corporation is seeing a construction growth with seven companies busy with constructions well underway within the Coega Development Corporation’s Industrial Development Zone. Construction taking place at the IDZ provides job opportunities for residents living in the Nelson Mandela Bay and about 1800 people are benefitting from the constructionrelated jobs. “Construction expansion of existing businesses is a sign of current investors’ business growth and an improving economic climate,” said CDC head of marketing and communication, Dr Ayanda Vilakazi. Companies currently under construction include leading gas suppliers Air Product (R300m investment) and Afrox (R300m); electricity generator Dedisa Peaking Power Plant (R2.2-billion); while cold chain logistics facilitators Vector Logistics investment is valued at (R140million); Digistics expansion (R30million); ID Logistics (R30-million) and UTi Distribution (R30-million).

The slab for the Afrox office building is presently being cast and the aim is to have construction completed during the fourth quarter of this year. Twelve people will be employed once operational. More than a third of the work is completed on Dedisa Peaking Power Plant. On completion the plant will consist of two open-cycle gas turbines able to produce 335MW of electricity, which is roughly half of Nelson Mandela Bay’s power requirement. The establishment of the plant will provide value added assistance to a number of growing industries established in the IDZ, estimated to offer over 1000 permanent employment opportunities as a result of the supply of electricity to those industries. Air Products is firmly on schedule to commission the plant and have gas flowing to customers in the final quarter of 2014. Nine operational jobs and 42 constructions jobs are being created. Vector Logistics started construction in May this year and have created 120 construction jobs and 90

CONSTRUCTION BOOM: Workers at the Dedisa Power Peaking Plant people will be employed once operational. Digistics Digital Logistics has outgrown its current 2 285m² facility in Zone 1 of the Coega IDZ – a space it has occupied for six years – in favour of a larger 4 510m² facility. Construction of the new Digistics warehouse facility started at the end of May this year. There are 120 construction workers benefitting from the project and once completed 30 people will benefit from permanent jobs. ID Logistic will create work for 50 people once operational and during the construction phase 200 people would have benefitted

from jobs created. UTi Distribution currently operates from a 2700m² building but will be moving to a 2800m² building which is currently under construction thus increasing their capacity with a 100m². The new site is expected to be completed closer to the end of this year. Dr Vilakazi added that the CDC’s success as a “leading catalyst for socio-economic growth”, was due to the fact that the CDC not only provides a competitive investment location for investors but this is supported by value-added business services. Enquiry No: 2

July / August 2014

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EC Industrial & Business News

Six of the best

IX of the Nelson Mandela Bay Metro and surrounds’ leading women in government and private business stepped up to receive top honours for their successes at the Port Elizabeth Businesswomen’s Association’s (BWA) glamorous annual Regional Business Achievers Awards, held at the Boardwalk Hotel recently. Selected for their inspiring successes from a pool of 18 impressive finalists (three in each category), the 2014 winners are: • Corporate: Chantal du Pisani, Chief Executive Officer at Access Management, operators of the Nelson Mandela Bay Stadium • Government: Professor Heather Nel, Senior Director of Institutional Planning at Nelson Mandela Metropolitan University

• Entrepreneur: Kobie Potgieter, owner of Remax Independent Property • Emerging Entrepreneur: Sarisa Ferreira, owner of Areli Veg, (Patensie) • Social Entrepreneur: Thina Maqubela, of Ubuntu Education Fund (Grahamstown), and • Professional: Joanne Anthony, owner of Joanne Anthony Incorporated More than 90 businesswomen, not necessarily BWA members, were nominated this year from a wide range WINNING WOMEN – The winners of this year’s BWA RBAA of industries, with the 18 finalists are, from left, Joanne Anthony (Professional category), and ultimately six winners assessed and selected through audited judging Professor Heather Nel (Government), Sarisa Ferreira (Emerging Entrepreneur), Liepollo Pheko, National President of BWA processes. The final Panel of independent Judges represented a broad South Africa, Kobie Potgieter (Entrepreneur), Chantal du Pisani (Corporate) and Thina Maqubela (Social Entrepreneur). cross-section of leaders in business, Enquiry No: 3 government and civil society.

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Ground-breaking international initiative for EC Development

astcape Midlands College, embarked on an international partnership during 2013 to improve its certification rate and to increase employability of its students. The college’s vision is to obtain a 100% certification and retention rate and 100% placement of its students by 2016. The college has campuses in PE, Uitenhage, Grahamstown and Graaff-Reinet. Recently, a high-ranking delegation from the Walsall College in the Black County Region in United Kingdom arrived in Nelson Mandela Bay to review the implementation of the outcome of the British Council’s Skills for Employability Programme partnership with the college. Manjeet Kumari-Lal, and Jayne Holt, of Walsall College were joined by EMC delegates at the British Council International Conference held in Johannesburg in late July 2014 where the partnership was showcased. Skills for Employability, a British Council programme, addresses the demand for skills in a global economy and international workplace. The programme allows national educational and training systems to better respond to labour market demands and learner needs. It further focuses on building strong relationships with industry and employers, governments and training providers to empower students. “It is notable that the vision of EMC is in line with what is being implemented at Walsall College. The partnership enhances the articulation of the out of the box thinking, which is an EMC trademark, to practical delivery. The benefits of this partnership will allow EMC to further develop and upskill local labour and emergent human resources in technical and vocational positions in the Eastern Cape keeping bestpractices of the global labour market in mind and in sight,” said Eastcape Midlands College Principal, Mr JJ Mbana. “We were delighted with the progress that has been made with the AaA (Accelerate and Advance) programme and learning company model. EMC have shown a real commitment to improving students’ employability skills. “ The AaA intervention pilot has resulted in an increase of 10% achievement on the NCV Level 4 mathematics said Jane Holt, Assistant Principal of Walsall College. Mbana said the programme will further augment the offering and performance of Eastcape Midlands College, which obtained a 73% NCV certification in 2013 and achieved 874 distinctions in the National Certificate Enquiry No: 4 (Vocational) exams.

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Tel: 0861 122 441 P O Box 1322 Wandsbeck 3631 Fax: (031) 266 7514 Email: editorial@ mediaevents.co.za www.mediaevents.co.za Managing Director: Janet Coom Editor: Jacqui Harris Email: editorial@mediaevents.co.za Sales & Marketing Manager: Cheryl Murphy Email: cheryl@mediaevents.co.za Any news items, press releases, articles and photographs relating to business and industry in Eastern Cape Industrial & Business News are welcome. All contributions will be considered for publication. Disclaimer: The editor and management of Eastern Cape Industrial & Business News make every effort to ensure the accuracy of the contents of this publication. However, no warranty is made and no responsibility will be borne by the editor or management of consequences of any actions based on information published. The views and opinions expressed in this publication do not necessarily reflect those of the editor and/or management.

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July / August 2014

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EC government to address E L port coal loss

Jeffreys Bay wind farm inauguration D riving along the N2 it is impossible to miss Jeffreys Bay Wind Farm’s magnificent wind turbines standing proud as part of the country’s largest operational wind farm. Wednesday, 9 July 2014 saw the inauguration of this project, marking the completion of a six year journey through development, financing, construction and finally into operations. The 138MW power plant is a product of the South African Government’s Renewable Energy Independent Power Producer Procurement Programme and will supply enough clean renewable electrical energy to meet the needs of over 100 000 average South African households. “In a country struggling to meet its escalating demands for electricity we are proud to be contributing around 460 000 megawatt hours (MWh) per year of electrical energy to the national grid,” said Mark Pickering, General Manager of the Jeffreys Bay Wind Farm. He continued saying, “It’s remarkable to consider that by the end of this year the country will have more than 400 turbines reaching into the sky, all helping to reduce the use of fossil fuels and precious water in meeting the country’s energy requirements.”

Over the next 20 years, the local communities living within a 50km radius of the Jeffreys Bay Wind Farm will benefit from a range of socio-economic development programmes. These programmes will focus on early childhood development, as part of a crèche support programme; numeracy and literacy interventions at primary school level; mathematics and science programmes at secondary schooling level; and scholarships for engineering-related studies at tertiary level. The company will also establish an enterprise development programme that will initially focus on supporting emerging black farmers in the area. The Amandla Omoya Community Trust, which owns 6% of the project, will run further developmental programmes to benefit the local community. “It is vital that renewable power brings positive benefits to local communities” added Pickering. Pickering continued saying, “Wind farms across the country, both operational or currently under construction, will invest over R5 billion of their revenue into socio-economic and enterprise development initiatives over the next two decades.” “They will also create substantial employment opportunities, training and skills trans-

fers. All of which are essential for the future of both the industry and the country”. “Our Project has received resounding support from the Kouga Municipality and the surrounding communities. For this we are most grateful and we look forward to a long and mutually beneficial relationship,” concluded Pickering.

Jeffreys Bay Wind Farm MILESTONES: • Construction Commenced: December 2012 • Transportation of the first Turbine Component: 22 July 2013 • First Turbine Erected: 26 September 2013 • All 60 Turbines Erected: 27 February 2013 • Supply Power to Eskom Grid: 20 December 2013 • 1 Million Man Hours Worked without Lost-Time-Incident: 27 December 2014 • 1,265,065 Man Hours Worked without Lost-Time-Incident: 31 April 2014 • Total Jobs Created: At the peak of construction, there were 602 people working on site, 45% of which were from the local communities in the Kouga Municipality. • Transportation programme completed: 19 February 2014 – having covered over 110 000km • Fully Commissioned: April 2014 • Commercial Operations Enquiry No: 5 Date: 15 May 2014

he Eastern Cape Department of Economic Development, Environmental Affairs and Tourism will be “actively engaging with Transnet in the development of a focused strategy for the Port of East London,” MEC Sakhumzi Somnyo (pictured) has told the Eastern Cape Legislature. Presenting his Policy Speech, the MEC said it was “unfortunate” that when announcing their annual results on June 30 Transnet had revealed that a dedicated coal terminal would no longer be built at East London and that the coal from the Elitheni Mine would be exported through the Port of Ngqura. He said that although the decision did not amount to a loss to the province, “it leaves East London at a disadvantage,” adding that the East London port was “an important part of attracting investment into the ELIDZ”. The MEC said that the work of the department compelled it to collaborate with other organisations such as Transnet which had committed to invest over R21 billion from 2013-2020 in the Province. Key projects, he said, included the expansion of the Port of Ngqura as a transhipment hub; relocating both the Tank Farm and Manganese Terminal; the expansion of the Port Elizabeth Port to be an automotive export hub; the extension of the Port of East London to include an expanded container terminal and the operationalisation of strategic railway branch lines. The MEC added that a working committee had been established with the Department of Public Enterprises “to plan jointly and monitor” the work of State Owned Companies in the Province, adding that the focus would be on Transnet, Eskom, InfraCo Broadband, SAFCOL and Sentec. With regard to Project Mthombo, the oil refinery planned for the Coega IDZ, he said the feasibility on the project was “reaching finality and would be completed in December”. Enquiry No: 6

July / August 2014

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EC Industrial & Business News

Keeping positive in tough times T o be South African, these days, is to live with uncertainty. For business, now is the time to plan and prepare, to focus on concrete steps that can be taken and positive plans. We are responsible for building our own certainty.

It is important to expand our often narrow view of the South African economy to include major government investment and subsequent private sector investment. The State of the Nation address was an unrivalled opportunity for President Jacob

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Zuma to provide strong, clear directives in response to severe concerns about the South African economy. It was welcome, therefore, to hear his commitment to extensive engagement with the private sector, to work together to overcome the inhibitors of growth in the economy. Where government funding is spent, private sector investment will follow. The news that Transnet is moving swiftly ahead in establishing the manganese corridor between the Eastern and Northern Cape holds a great deal of promise for our region. Over the next five years, R26 billion will be put into a rail infrastructure upgrade and into the building of an export terminal at the Port of Ngqura. The first manganese will be exported from Ngqura in 2019, just five years from now. We’re well into the second year, now, of Transnet’s R300 billion investment into South Africa’s transport infrastructure. Bold commitments, such as the commitment to beginning the manganese corridor in Nelson Mandela Bay, paint a healthy and hopeful picture. It is imperative that the vital role of business and civil society be acknowledged, that strategic partnerships be sought and built, and that every South African citizen recognise the role he or she must play to ensure a participative and competitive economy and a sustainable future for all. Premier Phumulo Masualle’s State of the Province address injected new impetus into the commitment to develop our province as the energy hub of South Africa. Alternative and renewable energies carry huge potential to change the fortunes and the futures of the people of the Eastern Cape. The Premier’s commitment to the pursuit of the Project Mthombo, too, is a direct acknowledgement of the opportunities available to grow and develop the Eastern Cape economy. The Business Chamber and its strategic partners have long advocated for the establishment of the oil refinery at Coega for its promise of job creation, security of supply, the up- and downstream opportunities it offers towards the diversification of the Eastern Cape economy, which all points to considerable, positive

bay view Kevin Hustler

socio-economic impact. The diversification of the Eastern Cape economy is vital if we are to see the levels of growth needed to sustain the province and its people. Diversification opens the way to increased foreign and local direct investment. Armed with the good news that the Special Economic Zones legislation is now final, business would like to see a progressive drive towards a reduction in the red tape that hampers investment, improved co-ordination and investment promotion, and increased investment incentives towards streamlining the business environment. The Coega Industrial Development Zone will become a Special Economic Zone (or SEZ), and will enjoy economic incentives, such as a 15% tax rate for investors. In February this year, Business Day Live quoted Executive Manager of Business Development at the Coega Development Corporation, Christopher Mashigo, as saying that certainty about incentives that have not been available to IDZs “is key to making Coega’s case stronger in its efforts to secure new investments in the midst of serious competition”. The Coega IDZ has, to date, attracted billions of Rand in public investment. Major development in the IDZ over the past few years has included investments by the likes of DCD Wind Towers, First Automotive Works (FAW), Afrox, Agni Steels and Air Products, to name but a few. Within the strong commitment on the part of government to fund much-needed infrastructure projects throughout the country, we see a solid platform for private sector investment. And, through the growth of an enabling environment for business, it will indeed be possible to work towards prosperity, even in the face of troubling uncertainty.

Gas a stepping stone to low-carbon economy

fter 250 years of fossil-fuel fired growth, we are finally bumping into planetary limits. This was among several messages conveyed to delegates who attended Gas Week 2014 in Johannesburg recently by Dave Collins, Associate Director of MAC Consulting, one of South Africa’s leading management consulting groups focused in mining; oil, gas and chemicals; financial services and telecommunications. Gas is currently receiving a lot of attention globally, but especially in South Africa, where

either gas or nuclear, or both, could replace coal as the main generator of electricity. Collins maintains that gas might, through emissions reduction, be a stepping stone to a global low-carbon economy and still provide the amount of energy needed to support the world’s nine billion increasingly demanding people by 2050. “But,” he cautioned, “this still won’t be enough to fix the global warming problem, bearing in mind that the current trajectory is for around 4°C by 2100 - and 4°C globally means 6-7°C in Southern Africa” He noted that the major published energy forecasts and scenarios were on average suggesting an average absolute increase in demand for fossil fuels of 35% by 2040. Exacerbating the problem is that countries are largely focussing on providing energy security and energy supply right now, with inadequate responses on emissions reductions from energy consumption in the years or decades to come. Collins said that for many reasons, it will take decades to shift significantly away from fossil fuels. Enquiry No: 7

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New Wild Coast towns planned

Third rail to road depot for EC

friSam is poised to increase its market share in the Eastern Cape with the opening of a third rail to road depot in the province — this one in Markman Industrial, Port Elizabeth - is intended to supplement the company’s existing depots located in East London and Queenstown. The new depot, efficiently serviced via its own rail siding, incorporates a 1 000 ton

bulk cement silo capacity and a 3 600 ton bag holding capacity. “Historically we’ve enjoyed a very strong presence in the eastern side of this province, supplying these areas from our Ulco plant in the Northern Cape via the two rail to road depots,” Grant Neser‚ AfriSam sales and marketing executive‚ says. “This allows us to take advantage of the cost effective rail rates down to the depots, allowing AfriSam to focus on the last leg by road.” “Although we could have serviced the western area of the province directly from Ulco or via East London, after looking at all the options it was found that the most cost effective way to provide the quality service we want to offer in this area would be with another fully-fledged rail to road depot. The 1,8 ha site has been sized to ensure we have a significant amount of bulk capacity to support customers who use bulk cement in the vicinity of Port Elizabeth. At the same time, we’ve increased our bulk capacity in both East London and Queenstown to entrench security of supply in the Enquiry No: 8 province.”

B-BBEE compliance made easy

outh Africa’s first and only book on the Amended Broad-Based Black Economic Empowerment Codes of Good Practice, which also links to a scorecard calculator application, aims to help users understand the new regulations as well as calculate their B-BBEE scores. South African organisations will be audited for compliance using the new codes from April 2015. This book, The Practical Guide to the Amended B-BBEE Codes of Good Practice, published by leading content and technology solutions provider, LexisNexis South Africa, is a must for those needing to understand and apply the new transformation regulations, as well as BEE registered auditors. The authors, Brigitte Brun, Chief Operating Officer of a SANAS accredited and IRBA approved Verification Agency, and Maxi-Lee

Machado, Managing Member of ET Consult, have years of experience in B-BBEE consultancy and the verification process advisory. Key benefits of the book and linked calculator application are that they enable organisations to calculate their B-BBEE score easily, before they reach the verification stage. The toolkit includes a scorecard comparison schedule covering every issued sector code enabling users to track progress and take appropriate action to ensure compliance and continuous improvement. Users can also access the latest legislative changes using a website address provided in the book. The book has been endorsed by Sandile Zungu, Executive Chairman, Zungu Investments Company (Pty) Ltd, and member of the Presidential BEE Advisory Enquiry No: 9 Council.

he Eastern Cape Department of Economic Development, Environmental Affairs and Tourism (DEDEAT) is considering the establishment of five new towns on the Wild Coast. The proposed towns will be at Qolora Mouth, Qora Mouth, Mthatha Mouth/Mdumbi, Hole-inthe-Wall/Coffee Bay and Mzamba, essentially the Wild Coast Casino area. The Wild Coast Environmental Management Plan, published in

the Provincial Gazette, points out that this is “an economic development issue rather than an environmental one”. As a result it will be driven by provincial government development agencies and especially by municipalities. It stresses however that where there is an intention to carry out large-scale development at these proposed towns “tangible, credible infrastructure development plans must be in place before

investment is invited or development planned”. The Management Plan points out that the Wild Coast faces “a number of serious challenges” in relation to waste management. Therefore before the department will agree to the establishment of any new towns the local municipality within which it is situated must have an approved Integrated Waste Management Plan. It stresses that any authorisation granted by DEDEAT will include a condition that authorised development may only be occupied or used once the required waste management infrastructure and services “are actually in place”. It cites as an example that construction of a new resort may begin and be completed but will only be allowed to accommodate guests “if waste management infrastructure and services are in place”. In addition, a credible Water Services Development Plan must be in place with special emphasis on bulk supply. The Management Plan adds that for developments to be sustainable these issues must Enquiry No: 10 be addressed first.

July / August 2014

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EC Industrial & Business News

SMEs hamstrung by labour legislation

Holbrook’s Voice

he Border-Kei Chamber of Business has always understood that SMEs play a vital role in the continued economic success of the Eastern Cape and South Africa as a whole. However, over the past few years the government has implemented more and more stringent labour laws and regulations which are now having a profoundly negative impact on how SMEs operations. Whilst business is continuously asked by government to drive job

creation, labour legislation simply becomes increasingly restrictive, especially to small business – measures which have gone as far as forcing some businesses to close down. There remains limited incentive programmes focused at small business to employ people – this must change if government wants to alleviate the 24.1% unemployment rate and create the six million jobs it talks about. Perhaps Minister Oliphant needs to take stock of the labour situation in South Africa and review, as government, the policy approach it has to labour legislation? The majority of our members feel that the legislation currently in place is

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far too restrictive and is a barrier to their business growth and thus growth of the economy as a whole. According the latest Stats SA Labour Force Survey, it is important to note that although the Eastern Cape showed a positive employment growth the definition used by Stats SA for an employed person is “persons aged 15 – 64 years who, during the reference week, did any work for at least one hour, or had a job or business but were not at work (temporarily absent).” This we believe portrays a skewed view of the “on the ground” situation, especially where it is quoted that in quarter 4 of 2013 there were 653 000 job gains – where have these jobs been created? Because we certainly do not agree with these figures. Oliphant said last year that amendments to the Labour Relations Act would assist in limiting the exploitation of workers and to ensure decent work for all. “The amendments also seek to bring the provisions relating to child labour in line with interna-

tional standards and to strengthen the mechanisms for enforcement of basic conditions of employment, including wages.” There are a number of acts which are to be amended and include Labour Relations Act, the Basic Conditions of Employment Act, the Employment Equity Act, and the newly-introduced Public Employment Act – all of which have inherent impact of conducting business. These changes to the business climate do not go unnoticed either. According to the World Bank, South Africa was last measured at 41 in 2013 for the ease of doing business index (1=most business-friendly regulations). We concede that at 41, South Africa still ranks favourably to many countries on the index, but it remains a concern that with the pending changes to the already rigid legislation, that South Africa will become an increasingly less favourable country to do business in. As well as what I have stated

above, South Africa unfortunately suffers from a case of ambiguous legislation. Our legislators are slack; the legislation drafted is ambiguous and when applied to the SME playing field creates a minefield of problems. Sometimes I ask myself, “What is the intention of this piece of legislation?” – one begins to worry when such questions are asked of oneself. Case in point is the new BEE Codes and how they can be practically implemented by SMEs and all organised business in general. The new codes are an absolute minefield of uncertainty to the layman and sometimes even to the most qualified labour law practitioner. To this end the BorderKei Chamber of Business will be hosting a B-BBEE Codes Update business breakfast with Jonathan Goldberg, one of the premier labour law practitioners in the country to attempt to make sense of these new regulations and assist our members in putting them in a position to effect the requirements of the legislation.

BRICS Bank will benefit business

he formation of a BRICS New Development Bank was recently announced at the 6th BRICS Summit, and is aimed at mobilising resources for infrastructure and sustainable development projects in developing nations. While the head office will be based in Shanghai, the BRICS New Development Bank will have its African regional branch located in Johannesburg, South Africa. Charles Brewer (pictured), MD of DHL Express Sub Saharan Africa, says that the announcement of the formation of the BRICS New Development Bank and South Africanbased regional branch is a significant milestone in fostering trade between South Africa and other BRIC (Brazil,

Russia, India and China) economies. He says that the establishment of the New Development Bank will assist in removing key economic stumbling blocks for South Africa’s economic growth and further position the country as a gateway into Africa. “It has been reported that the bank is scheduled to begin lending in 2016 and that they will be open to membership by other countries. This could bode very well for other African countries and the development of infrastructure within these regions where there is a huge need for this investment.” “Within the business of logistics, we often witness how the quality of infrastructure in a country can positively or negatively impact economic perfor-

mance. For instance, in many African countries, infrastructure is a major constraint on doing business. With underdeveloped road and rail networks, and some cities only being serviced by one flight per week, infrastructure and connectivity are among the most pressing problems limiting growth,” says Brewer. He says as a comparison, according to 2013 data by the World Bank pertaining to air transport, South Africa reported 185 963 registered carrier departures worldwide, while other BRICS nations, Brazil and India reported 958 782 and 681 063. Enquiry No: 12 respectively.

High municipal rates affect commercial property costs

nterest rate increases and escalating municipal costs, including electricity and water costs, maintenance services and municipal property rates, are resulting in commercial properties becoming very expensive to maintain, and in turn is lowering the demand for this type of property in South Africa. This is according to Gary Palmer, CEO of Paragon Lending

Solutions, who says that five years ago municipal bills as a percentage of operating costs were around 40%. “Today these costs have escalated to around 66% of operating costs. The impact is continued pressure on net property incomes, especially where landlords are unable to pass on cost increases to tenants. Increasing costs and the downward pressure on rentals has resulted in a margin

squeeze in this sector.” He says that consequently commercial property portfolios are becoming too expensive to manage, and the inability of tenants to absorb these increases is weighing commercial property owners down. “With interest rates and municipal charges increasing steadily, it will prove difficult to obtain the required funding for commercial property from traditional lenders such as banks, as the high costs that commercial property owners have to endure leaves little margin for them to meet the banks strict lending covenants as well as draw sufficient income for themselves. We will see the banks reducing their loan to values for commercial property deals in the next few months.” Palmer cautions that the sharp increases in municipal rates are unsustainable not only for commercial property owners, but for the tenants too as commercial property owners have to pass on the increase rates to tenants. Most of the tenants cannot afford the increase and will in all probability not extend their leases when the lease term expires. He says that this will lead to high vacancy rates within the Enquiry No: 13 industry in the near future.

July / August 2014

EC Industrial & Business News

MATERIALS HANDLING, BULK HANDLING & LOGISTICS

Delivering results for port operations

Max Slabbert Stevedore Manager, Bidfreight Port Operations, Cape Town branch, left receiving four T870 Bobcat compact track loaders from Hein Dornbrack, Bobcat Sales

our Bobcat T870 compact track loaders were recently delivered to Bidfreight Port Operations for trimming of bulk cargo inside ship hatches at Cape Town and Port Elizabeth ports. Bobcat Sales Representative, Hein Dornbrack, explains: “The eight or twelve cube grabs on the ship which are used to discharge

cargo such as soya, wheat or fertilizer, cause uneven spread of the cargo and in turn affect the ship`s stability. The Bobcat loaders are used to push cargo around, levelling hatches ‘to trim the ship’. Often only part of the cargo is discharged while the remaining cargo continue on with the ship to the next port. However, it is essential from a safety point of view that the cargo is level before the ship sails. We also fitted the machines with Lifting Kits so that they can be easily loaded and discharged from the ships.” Bidfreight Port Operations, a member of the Bidvest Group, is one of the largest providers of in-port logistics in South Africa, with operations in every commercial cargo port in the country. Their areas of expertise include; warehousing, stevedoring, transportation and terminal operating services. “Once a ship docks, time is of the essence and we simply cannot afford down time,” explains Max Slabbert, Stevedore Manager, Cape Town branch. “It is all about time and tonnage. We need reliable equipment to get the job done right the first time. Bobcat was the only company able to supply the type of unit that we required - compact yet still powerful. The Bobcat machines comfortably handle prescribed volumes; a faster discharge of cargo means that ships spend less time in the ports.” The T870 is the largest in the Bobcat compact track loader range and is therefore also heavier. “The larger size allows for the ultimate

pushing power in its category. This being said, the T870 has a track width of 450mm which gives it a ground bearing pressure of only 32.4 (kPa) which is particularly impressive if one considers that the average human has a ground bearing pressure of around 55 (kPa). Decreasing the ground pressure increases the flotation, allowing easier passage over soft terrain or cargo. This is an absolute necessity given the type of cargo that our client discharges,” Dornbrack explains. Slabbert adds that operator safety and com-

fort is also a very important consideration,” and here too the Bobcat units come up trumps. The spacious pressurized cab offers first class comfort with panoramic visibility and protects the electronics from dust and water ingress. The cabs are equipped with heating, airconditioning systems, selectable joystick controls and full colour instrumentation panels for easy visibility. As ship trimming is a specialised area of expertise, Dornbrack says that driver and maintenance training will be undertaken in Enquiry No: 14 conjunction with clients.

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Cost effective crushing solutions

ilot Crushtec International has established its local and international reputation on the simple premise that it has built up a business not by selling equipment but by providing customers with innovative crushing and screening solutions backed by excellent products and service. A case in point is the Pilot Modular/TRIO MC90 cone crusher recently supplied to Ugie Mac Quarry in the Eastern Cape Province. The customer was looking for a cost effective method of producing 13mm and 19mm stone and <8mm dust for concrete applications in relatively small quantities. The use of contractors was proving to be a costly exercise but volumes did not justify the purchase of a mobile cone crusher. National sales manager Nicolan Govender and his team devised a simple solution to the dilemma by suggesting the integration of a modular skid mounted cone crusher with Ugie Mac Quarry’s existing mobile jaw crusher and screen. “We found that the addition of the Pilot Modular/TRIO MC90 and two Pilot Modular conveyors – a 12 metre MC800 and a 4 metre MC800 – provided an efficient and affordable answer to his problem. An added bonus is that these products are invariably available ex-stock so we were able to give a rapid response,” he says.

The existing jaw crusher feeds material into the mobile screen and oversize material is processed by the newly-installed cone crusher which in turn feeds product back to the screen. The combination is producing quality material at a rate of up to 90 tonnes per hour and Ugie Mac Quarry director Jason Kashula is impressed not only with the performance of his latest acquisition but his experience in dealing with Pilot Crushtec International. “Until recently stone crushing and screening has not played a major role in our business but we bought a jaw crusher back in 2010, followed by a screen. Pilot Crushtec International’s after sales service and support was excellent, and when we needed advice to go forward we didn’t think of talking to anyone else,” says Kashula. Ugie Mac Quarry is well-established in the region and its name is a combination of Ugie and Maclear, the two towns it is situated between. Founded in 1974, the company has more than 50 permanent employees and is active in quarrying, plant hire, civils and conEnquiry No: 15 struction.

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July / August 2014

materials handling, bulk handling & logistics

EC Industrial & Business News

New approach to an old business

ewly created Imperial Managed Logistics is one of the big success stories emerging from Imperial Logistics’ consolidation process, which last year saw the group’s structure simplified and its capabilities consolidated, reports Chief Business Development Officer Cobus Rossouw. Imperial Managed Logistics encompasses the longstanding reputations and experience of Broco, Cargo Africa and TranSend Container Logistics, so it is certainly not a newcomer to the industry. What is new, Rossouw reveals, is Imperial Managed Logistics’ unique business model, which redefines customer and sup-

plier relationships, as well as transport supply and demand. The company manages logistics in an asset-light environment. “So, unlike most transport companies, Imperial Managed Logistics is not constrained by its assets. The company seeks to understand clients’ requirements, and then make transport capacity available to serve that need.” This is done through a dedicated fleet of 450 vehicles - comprising both Imperial Logistics vehicles and suppliers’ vehicles - and formal partnerships with some 1 000 sub-contractor transporters. Unlike traditional transport brokers, Imperial Managed Logistics

has contracts in place with its transport suppliers – so that clients can be guaranteed of transport capacity, and sub-contractors can be assured of a sustainable business. “Our engagement with customers and suppliers is based on a unique model that is proving a recipe for success, and garnering praise – and business – from clients like Tiger Brands, Simba, Sasol and Brandhouse,” Rossouw says. Imperial Managed Logistics’ contract for primary distribution services for JSE-listed Tiger Brands will see the company transporting close to 50 000 loads per year for the FMCG group. A factor that contributed to this contract win – and is one of the outstanding features of Imperial Managed Logistics’ operating model – is the visibility created for the client. “Historically, in transport, visibility has been fragmented. With Imperial Managed Logistics

as the client’s single point of contact, end-to-end visibility - of all loads on all routes - is assured.” It is provided via four 24/7 operations offices, all equipped with live satellite tracking. “This enhanced visibility enables improved decision making. It makes it

possible to change the demand for transport by taking a more professional approach to understanding this demand,” Rossouw states. Clients also reap the benefits of Imperial’s expansive network and geographic footprint. “But,” Rossouw stresses, “each client’s requirements are managed individually, and there is no one-size-fits-all transport solution.” Its flexibility and scalability are further benefits of the Imperial Managed Logistics model. “This scalability enables us to cater for clients with very different requirements in terms of volumes, and for loads ranging in value from R125 000 to R8 million.” The company did some 220 000 loads last year, with up to 1 000 loads a day at peak, Rossouw reveals. Specialised vehicles are available to Imperial Managed Logistics through different service providers. Enquiry No: 16

Increasing support for side-loaders

eading supplier to the mining, construction and manufacturing industries, Atlas Copco, has joined the many South African companies that are seeing the benefit of Goscor Lift Truck Company’s (GLTC) Hubtex specialised sideloaders. “The versatility of the Hubtex and its ability to handle long loads and work at the required height in narrow aisles - attributes which a conventional forklift cannot offer – have, in a short time, made a palpable difference in the warehouse,” says Tammy Cairns-Buhler, Atlas Copco Distribution Centre Manager. “We had been told of the Hubtex advantage by one of Atlas Copco’s divisions in Sweden, which spurred our interest,” says Cairns-Buhler. “And when we saw it demonstrated it was immediately apparent that this was the solution for our business and that conventional forklifts were not really fit for our purpose. We have not been disappointed in its performance and look forward to seeing even better productivity down the line.”

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Atlas Copco bought the Hubtex MQ 30, which is one of the world’s most popular electric sideloaders. It has multi-directional steering for the handling of pallets and long loads. Characterised by its compact design, it is especially suited to narrow aisle storage applications. ”The smallest possible aisle width can be achieved because of the choice of different cabin versions for individual requirements.” explains GLTC MD, Darryl Shafto. In fact the Hubtex electric sideloaders are the ultimate in versatility offering users a large choice depending

on their particular application. Apart from the choice in cabs, they can be equipped with a short chassis for block stacking and they can be used both indoors and outside. Equipped with a travel motor which is constructed in an upright and water-protected manner it can work in poor weather conditions without hesitation. The MQ 30 has a lifting capacity of 3-tons and a lift height of up to 10m. Shafto says that while there is still a plethora of S.A. companies using inappropriate machines for their particular applications, there are many companies like Atlas Copco which are taking note of the way Hubtex is improving efficiencies in other South African companies and many European companies. With a process that was ‘green’ in nature, it was logical to acquire an environmentally friendly, ‘green’ stacker: “We had all but decided to invest in an additional three-wheeled fourway stacker”, explains Peter Weller, Dauerholz AG operations manager. Enquiry No: 17

Latest in weighing transmitter technology

nstrotech, a Comtest Group company, has announced the launch of their latest multi-function weighing t r a n s m i t t e r, the model 6004MF version II. It’s a powerful, compact, field-mounted unit that can be selected for a variety of weighing functions. Specifically designed for servicing organizations, weighing equipment manufacturing companies and individual users, the 6004MF is a single electronic unit that can be used for almost any application in the weighing industry. The 6004MF finds application in the areas of loadcell transmitting, belt-weighing, loss-in-weight transmitter, through-put weighing, bag-filling, batch-weighing and a dynamo meter. A multi-function unit allows the user to keep one spare that can replace any of the above-mentioned functions in the field. This also reduces the stock holding requirements for manufacturers, integrators and factories. The 6004MF weighing transmitter is housed in a rugged, powder-coated, cast aluminum housing with a splash proof keypad. It features a clear 20mm 6-digit LED main display and auxiliary information LCD display, with user-programmable function keys, digital Enquiry No: 18 inputs and relay outputs.

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2014/06/27 10:38:25 AM

July / August 2014

materials handling, bulk handling & logistics

EC Industrial & Business News

First in intralogistics

014 promises to be very exciting with the launch of many new products and innovative ideas including Semi and Fully Automated solutions from STILL Germany, says Kathy Hendricks, Divisional Director of Value Materials Handling who are the sole Distributor for the Still Brand in South Africa and other African countries. Their philosophy is looking to harmonize optimization of the six factors that determine the future efficiencies of every company’s intralogistics. These six factors include: • Power • Precision • Ergonomics • Compactness • Safety • Environment The Industry will see the world of warehousing equipment turned on its head with the introduction of the Li- Ion batteries. This will allow break even on return of investment in 1.4 years. Currently the lead acid batteries, only starts giving return on investment from 2.5 years. This technology will also improve productivity; one battery will last for two shifts. The physical size of the battery is half the size of current bat-

teries, which means that the machine is smaller and easier to manoeuvre. This should lead to less abuse of racking and product. The batteries are completely maintenance free. Charging periods of less

than 1.5 hours means a reduction in electricity costs. These batteries will also have double the energy and double the life cycle in comparison to lead acid batteries. This technology will be rolled out initially on the Electric ride on pallet 1 to 3 Ton Range and will be available from mid-2014. 2014 also sees the launch of the new STILL reach truck. The current reach truck is seen as the benchmark in Europe and will now be able to offer lifting heights of up to 13m, and included is new development in mast technology. The company has implemented a new dampening system that will improve the stability of loads at greater heights. This dampening system will decrease the oscillations of the mast when lifting heavy loads to high levels. Normally when drivers lifts loads to eight metres and beyond; they will find that the mast still has quite a bit of movement and needs to stabilise before they can place the pallet on the racking. This dampening system ensures that the mast will come to a complete stand still within six seconds. The design on the cold store cabin has changed slightly, quality has not compromised and the cab remains at the top of its class when it comes to safety and driver comfort.

If you want to get a job done properly…

he revised B-BBEE codes announced by government last year have made skills development one of the areas that South African companies must focus on, if they wish to remain compliant. In effect, the revised codes amount to official acknowledgement of a policy that many companies have already recognised as vital to long-term sustainability and expansion. Shortage of skills is perhaps the most important factor holding back growth countrywide, and the most effective solution is for companies themselves to invest in training and skills development directly. South African road-freight giant Cargo Carriers serves as an instructive case study in this area. “After rising fuel costs, the shortage of skills is the major challenge faced by road-freight service providers,” says Andre Jansen van Vuuren (pictured), Divisional Marketing Director of Cargo

Carriers. “That’s why Cargo Carriers is really enforcing training and skills development.” Cargo Carriers have been proactively engaged with the problem for several years. With the demise of the apprenticeship system, they have had little choice. “Of all the problems our industry is facing, the skills deficit has been identified as a major issue, from a technical as well as a managerial perspective,” van Vuuren adds. “The shortage of technical skills affects general operational efficiency – our aim is to train technicians to a level that increases productivity and SHEQ (Safety, Health, Environment and Quality) standards. In the management area, it’s a business-sustainability issue. “It’s about managing a growing business, bringing people up from base-level so they really understand

South African joins global board

outh African born Ryan Flynn has been appointed Executive Vice President and Head of Business Area Equipment at Konecranes and as such will be a member of the Konecranes Group Executive Board. Konecranes is a world leading crane and hoist manufacturing and service company with branches in 48 countries, employing over Enquiry No: 21 12000 people.

Do you have an Enquiry? All articles end with an enquiry service number. Readers are encouraged to complete the form on page 28 should further information and contact details be required.

the culture of the company. “It’s about producing managers with Cargo Carriers in their blood.” The policy is already bearing fruit. In 2012, the first management trainee (enrolled in 2010) completed her training, and was placed within the group. “We’ve also had our first group of five diesel mechanic apprentices come through the training programme,” says Van Vuuren. “Two of them have successfully passed their exams, and are now qualified diesel mechanics. Diesel mechanics – technical personnel in general – are a major issue for us. There is most certainly a shortage of qualified diesel mechanics and when you do find them, they come at a very high cost. So the apprenticeships that we are funding can only prove fruitful for us in the future.” The company applies the same principle to management training. “We currently employ eight trainee managers,” continues van Vuuren. Enquiry No: 20

The design change sees better visibility for the driver in drive direction. The fully insulated cabin includes double glazed windows, not Macrolin or Perspex. It also features thermostatically controlled inside heating. Another product worth considering is the Tugger Train. The correct usage of this product will decrease traffic in already congested warehouses. Fleets can be reduced due to the many loads that can be moved simultaneously. Fewer machines means less energy consumption and also less chance for abuse and damages. The VNAP tool is a computer generated tool that the company use to assist customers when planning warehouses or restructuring current warehouses to optimise the performance of the logistical system. The company has been using

this tool since it gained the sole distributor rights three years ago. They are the only materials handling company in South Africa who makes use of this software. The VNAP allows for improved workflow, cost reduction due to optimising space in the warehouse and it also allows accurate planning for productivity. The exciting new I-Go system will be launched this year. This is an automation system that will allow for zero damages to machinery and racking. The customer also gets the guarantee that their goods are transported safely and that no products will be damaged. It will allow for increased productivity due to better uptime. The system will be implemented on the range of Turret trucks, Order pickers, Reach trucks and Pallet stackers. Enquiry No: 19

10 materials handling, bulk handling & logistics

July / August 2014

EC Industrial & Business News

Complete system for lithium-ion technology L inde Material Handling (MH) is incorporating the first warehouse technology trucks to feature lithium-ion batteries into its product portfolio. As an initial step, the Linde T16 to T20 pedestrian pallet trucks will be available to order with a load capacity of between 1.6 and 2.0 tonnes from September. The special feature of the solution from Linde is that the truck (including the truck control unit and electronics), battery and charger come together to form a complete system, the various components of which communicate via CAN bus. This set-up makes it possible to harness the full potential of the system in terms of performance,

and capitalise on all of the benefits offered by the new battery technology. In turn, this leads to considerable reductions in energy costs and increasing levels of productivity. At the same time, thanks to a series of precise adjustments and fine-tuning, the system complies with even the most stringent safety requirements. Out of all the alternative drive types available, lithium-ion technology presents the most opportunities in the short term. What’s more, it is expected that the segment for electrically powered industrial trucks will see a further boost in popularity as a result of this technology. After all, unlike the lead-acid batteries used previ-

See the Light Increased Payloads for Truck Builds

ously—which are particularly limiting when it comes to multi-shift use or applications that require significant amounts of energy— lithium-ion batteries boast an extremely high volumetric energy density. With lithium-ion batteries, twice the amount of useful energy can be stored in the same battery tray. In turn, this enables the truck to be operated for two shifts instead of just one, providing that staff use breaks as opportunities for interim charging. By taking this approach, companies operating industrial trucks are able to save time and costs associated with replacing batteries—as was required previously— without having to worry about reduc-

ing the battery service life through the interim charging process. Plus, equipment that previously needed to be kept for replacing batteries—such as a replacement frame with roller channel—are no longer required. The same is true of the areas in warehouses that had to be accordingly allocated for this purpose; this space can now be put to other use. What’s more, lithium-ion batteries are significantly quicker to charge, and do not require topping up or an equalising charge after the actual charging process itself in order to protect the battery. This also saves time and energy. Last but not least, intel-

ohnson Crane Hire, which operates the largest mobile crane fleet in Africa, is meeting an increasing demand for hire of cranes below 120 tons by continually adding units to its small crane fleet. “The demand for smaller crane hire comes from a broad range of industries, primarily transport, electrical and construction,” says Johnson Crane Hire Johannesburg branch and Kusile depot manager, Celenté Van Vreden. “Small mobile cranes are the solution when it comes to picking up anything that can’t be lifted by a forklift or a truck mounted crane. “ “It’s just as important to use a reputable crane hire company for smaller cranes as for the large cranes. We treat the smaller jobs in exactly the same way we manage the bigger lifts – identical standards are applied — and this has resulted in an excellent safety record and a highly satisfied customer base. “ “Operating within a highly competitive market, we differentiate ourselves

by providing all customers throughout South Africa and neighbouring countries with a total lifting solution delivered through our ‘SMART’ — Safety, Maintenance, Availability, Reliability and Total Cost Effectiveness — brand promise. These elements are delivered through highly structured company processes that ensure we pay attention to detail and comply with all the necessary legal requirements. Added value is delivered through rigging, logistics, lift engineering and CAD studies, as well as insurance.” “We don’t consider the job finished until the crane is safely back in our

Rolled Products | Extrusions

yard and I believe we go through all these processes better than anyone else in the market. The proof of this is in the amount of repeat business coming our way.” Johnson Crane Hire sends representatives to customer sites to conduct inspections before each lift to determine the most suitable crane for the job and whether the unit will be able to access the site, as well as to assess the viability of the area on which it will stand. Safety underpins all Johnson Crane Hire operations, with comprehensively documented and implemented safety systems that comply with all industry safety standards and thorough risk assessments conducted before each lift. There is a primary focus on proper crane maintenance, supported by the company’s national workshop in Johannesburg. To ensure its operators are properly trained, Johnson Crane Hire runs its own fully-fledged in-house training school for crane operators in Vanderbijlpark. Enquiry No: 23

erco has developed a lightweight trailer ideal for use in urban areas, especially around commercial hubs and other places where there are vehicle height and parking restrictions. The 6.9m trailer has a ten-pallet footprint load area and a payload of 8 tons as well as having a low deck height of 350mm with a body height of 2.9m, greatly simplifying loading and offloading operations for operators. Serco developed the vehicle - commonly known as a pony trailer - after receiving a request from their client, Coke Fortune, a distributor for Coca-Cola. Coke Fortune wanted something that was relatively low cost, highly versatile, durable and could be pulled by a small truck tractor. The truck tractor of choice was a rigid type Isuzu FRR500 converted and re-homologated to a truck tractor to cater for the pony and semitrailer combination. This was a tough assignment given there are no blueprints and the specification required certain unique requirements to make it work . The prototype was delivered in March and a second vehicle with further enhancements was handed over in May. The pony trailer has Whiting roll over side doors which are lockable for improved security. Also incorporated are aluminium floor planks fitted to a monocoque steel chassis resulting in a lightweight construction suitable to be pulled by the converted rigid truck tractor, which is economical to run even when Now available compared to a conventional 4x2 truck tractor. The UTILEV range of 3-wheel electric forklift trucks Serco design engineer, Travis Piek says, delivers reliable and cost-effective handling solutions, “the new trailer is proof of the benefits to be for a no-nonsense, uncomplicated approach to achieved through collaboration between the materials handling. transporter and trailer builder”. } Available in 2.0t capacity “The final result is a cost effective vehicle which offers improved payload over a } AC Technology drive and hoist motors with Curtis Controllers conventional truck body and the lower deck height makes for easier side access, coupled } A range of front-end equipment options is available to suit varying application requirements with the lockable side roll-over doors which makes for a versatile combination, ideal for } Ergonomically designed operator compartment with automotive layout local distribution.” }

www.hulamin.co.za or email hulamin@hulamin.co.za

Enquiry No: 22

Small crane fleet to meet increasing demand

Lightweight trailers for in and around commercial hubs

Think Future Think Aluminium Think Hulamin

ligent battery chargers that engage with one another open up new means of managing and optimising battery pools, and ensure maximum availability while reducing costs for energy and handling. The market launch of the warehouse technology trucks featuring the innovative battery technology will take place in two stages. The rollout will start with the Linde T16 to T20 pedestrian pallet trucks. The second stage is planned for early 2015 and will see other trucks brought onto the market. These include the Linde T16 to T20 pedestrian pallet trucks with increased battery capacity, the Linde T20 to T24 AP/ SP pallet trucks with driver’s standing platform, the Linde N20 and N20 HP low-lift order pickers, and the Linde P30C and P50C tow tractors.

Enquiry No: 24

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Utility you can trust™ For more information on the Utilev Range

Call: 0860 497837 www.utilev.co.za

July / August 2014

EC Industrial & Business News

materials handling, bulk handling & logistics

ccording to HFR Transport, one of South Africa’s largest independent refrigerated transporters, consistent pressure from numerous forms of taxes including cross-border taxes, e-tolls, inspection fees, vehicle licensing fees and more, render the road freight industry verging on uneconomical. With more taxes on the cards, such as the carbon tax now postponed to 2016, transportation companies must operate ‘lean and mean’. A key focus on financial stability for this industry means maintaining highly efficient operations that avoid time and cost wastage, so clients can benefit from optimized rates. For refrigerated fleets carrying foodstuffs and temperature controlled or sensitive products, the emphasis on time efficiency is even greater. Heinrich Schaefer, HFR Transport CEO says, “The drive for improved efficiencies is literally never-ending in this industry. As we are constantly faced with an increasingly competitive market and more pressure on our margins from taxes and legal requirements, the need for strategic solutions grows. Technology plays an important role here.”

Semi-automated storage solutions

PC Storage Solutions SA will be showcasing its warehouse storage solutions at Electra Mining Africa for the first time. The industrial tradeshow will be held from 15 – 19 September 2014 at Nasrec, Johannesburg and the company will be exhibiting two of its key semi-automated products: the Movirack and the Radio-Shuttle Mole Attracting an expected 38 000 visitors, Electra Mining Africa is southern Africa’s largest mining, industry, machine tools and electric trade show. APC Storage Solutions SA will be targeting representatives from the manufacturing, construction and logistics industries present at the event. Fred Albrecht, MD of APC Storage Solutions SA, is enthusiastic about the company’s maiden Electra Mining Africa presence: “With such large numbers of attendees, Electra Mining Africa offers a great forum for us to connect with both existing and new customers, not only showcasing some of our extensive product range, but positioning ourselves as a world-class warehouse storage solutions provider that is at the forefront of international trends and technology,” he explains. The Movirack and the Radio-Shuttle Mole are integral components in lowering the per-pallet cost of storage applications by providing handling solutions that eliminate or reduce the role of traditional material handling equipment, minimising allotted aisle space required for their operation to increase storage density. While these innovations enhance pallet density, they represented two separate approaches to achieve it. Movirack is a laterally mobile storage racking infrastructure which eliminates the need for static aisle spaces, opening individual lanes for access only when required in a fully automated, specified sequence. The Movirack retains direct access to each pallet bay, while increasing pallet density by as much as 80% to 120% for fast, frequent handling and reduced per pallet costs. The Radio-Shuttle Mole is deployed on a receiving racking lane by a forklift, from where it offers automated, remotecontrolled pallet conveyance to the designated bay. The Radio-Shuttle eliminates the need for static aisle space in between lanes required for forklift operation. Pallet moles can be deployed on either end of a lane, enabling both FIFO (First In First Out) and LIFO (Last In First Out) applications. In addition to increased storage density, the Radio-Shuttle reduces pallet handling time and lowers the risk of personnel and equipment accidents. Enquiry No: 26

Transportation fleets must consistently drive efficiency, say industry players

Clear communication lines between drivers and depots are critical for customer service. Schaefer, whose clients include some of the country’s largest retailers, comments, “We are committed to providing our customers with the best on time service delivery, ensuring compliance to transport legislation, responsible business practice and conformance to all safety measures.” Assisting HFR Transport in meeting these standards is its partnership with Tracker Business, leading tracking and fleet management solutions company. According to Schaefer, the flexibility that Tracker is able to deliver means the solution meets their needs head on in terms of integration and their specific fitment needs. “Importantly, the solution is also user-friendly and very proactive in terms of maintenance management, order dispatching and communi-

cation between drivers and fleet managers,” he says. Workflow is now dynamically managed in order to make the best use of the fleet on the day-to-day and HFR Transport has seen huge improvements in saving time due to the order dispatching function. Being able to track and trace vehicles using real-time information enables fleet managers to effectively plan fuel stops and necessary maintenance intervals. Navigation enables more deliveries to be made in less time and the speed and mileage of these jobs is also monitored so valuable opportunities for saving money can be identified. Mike van Wyngaardt, Executive for Tracker Business says, “Fleet efficiencies result in increased productivity so drivers are able to make additional deliveries in the same amount

of time. For the fleet owner, it means sweating their assets and earning additional revenue.” For customer-service orientated companies like HFR Transport, efficiencies mean they can keep their promise to clients of best service and reliability. With economic pressures placing a strain on resources and profitability across most industries in South Africa, the need to limit wastage and foster an attitude of productivity has never been greater. For the road freight industry, expenses such as e-tolls and rampant fuel costs are here to stay but seeking solutions that consistently drive efficiencies in key operations within the business can go a long way towards putting the breaks on unnecessary wastage. Enquiry No: 25

July / August 2014

12 materials handling, bulk handling & logistics

EC Industrial & Business News

Innovative locomotive technology has stood the test of time

CD Rolling Stock is a division of international manufacturing and engineering company DCD Group, and is recognised as a leading manufacturer and supplier of locomotives, wagons and bogies to railway, mining and industrial operations. DCD Rolling Stock general manager Petrus Mulaudzi notes that the most recent order for a 37-ton diesel hydrokinetic (DHK) Funkey shunting locomotive was made in late-2013 by a colliery in Botswana. “The 37-ton DHK Funkey locomotive is fitted with a 251 kW Cummins QSM11-L335 engine rated at 2 200 rpm and is coupled to an integrated Clark T4000 series torque convertor and transmission assembly. This provides it with enough power to regularly and consistently deliver vast quantities of coal from the mine site to a nearby coal fired power station,” he explains. Mulaudzi reveals that DCD Rolling Stock has

also received orders for its 24-ton and 35-ton DHK Funkey shunting locomotives from clients operating across the mining and industrial processing sectors over the past five years. “All the locomotives are fitted with an integrated air and vacuum braking system which allows for braking on all types of wagons, as well as independent locomotive braking. They also incorporate a metallic spring suspension and friction snubbers.” According to Mulaudzi, full instrumentation and safety circuits offer engine and transmission protection, while the power shift allows gear change to be carried out at full engine power and speed in any gear. “The cab and bonnet structure are fabricated from 3CR12 steel plate, offering excellent corrosion resistance and weather proof protection. The driver controls are ergonomically located on both sides of the operating cab to facilitate optimum

driver visibility.” The Funkey locomotive has been available in South Africa since 1930, and has remained a market leading product ever since. Mulaudzi does, however, admit that cheaper imports from China have proven to be a challenge for DCD Rolling Stock recently. “The African mining sector is cost driven and cheaper equipment is always appealing. The long term costs can prove to be far higher, as these locomotives are of an inferior quality and require considerably more maintenance and repair.” Mulaudzi indicates that DCD Rolling Stock also offers superior after sales and technical support. “A major trend among Chinese manufacturers is the tendency to deliver the locomotive onsite without providing any warranties or support. DCD Rolling Stock has established a

strong presence in Africa, and is able to send a qualified and experienced technician into the field, should the need arise.” Looking to the future, Mulaudzi believes that the greatest potential for growth lies in the burgeoning African mining sector. “Rapidly developing mining sectors such as Zambia and Ghana require highly durable, yet cost effective and simple locomotives for transporting ore. Having proven to be ideally suited to harsh African operating conditions over the past eight Enquiry No: 27 decades,” he concludes.

Expanded metals aid security in warehouses

xpanded metal has fast become a popular material for securing individual areas within all types of facilities. One of the main uses in this particular application is in inventory holding sections of manufacturing plants and warehouses. When compared to conventional fencing, expanded metal offers increased security coupled with unimpaired visibility. Elaine van Rooyen, marketing manager at Andrew Mentis, says expanded metal offers numerous advantages over ordinary welded or diamond mesh. “Unlike conventional materials, expanded metal is difficult if not impossible to cut. Numerous strands have to be separately cut before an opening can be made,” Van Rooyen explains. Essentially expanded metal is

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Our combination of multi-faceted handling equipment means that Linde machines are perfectly equipped for big jobs, small jobs and everything in between. With our comprehensive logistical know how, Linde has fast become the industry symbol for superior quality, seamless functionality and innovation. Available to lease, rent or on hire purchase, investing in Linde machines ensures the remarkable efﬁciency of each member of our family.

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For more information on Linde dealerships, products and services contact us on Tel : +27 41 487 3267 or visit www.linde-mh.co.za

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sheet metal that has been slit and expanded into a network of diamond shaped meshes. There are no welds or joints which can be unravelled or work loose in the expanded metal sheets. Expanded metal sheets are also more impact resistant that other fencing materials. While providing an aesthetically pleasing security barrier,

the expanded metal also allows unimpaired vision and free passage of air into enclosed areas. “The diamond mesh configuration does not offer hand or footholds, and the exposed edge on the top section makes it extremely difficult and dangerous for the intruder to scale.” Expanded metal is normally supplied unpainted, but readily lends itself to any of the normal finishing processes such as painting, stove enamelling, plating and galvanising. It can also be produced in 3CR12 and stainless steel should the application warrant this type of increased protection. Van Rooyen says that expanded metal offers the same level of flexibility as conventional fencing materials and can be tailor made for specific application requirements. Enquiry No: 28

Using flexible PVC for door openings

trip curtains are the economical solution for enclosing all internal and external apertures. The curtains helps with the effective reduction in heat and cold loss, and the containment of noise and dust. This improves the working environment and increases employee comfort. Transparent strips formulated from a PVC compound are designed to combine high clarity with mechanical strength due to an outstanding degree of flexibility. The clear strips will not interfere with natural light and will allow unlimited access to vehicles and pedestrians under conditions from +60° to -45°. Available in various widths and thicknesses (200 x 2mm, 300 x 3mm and 400 x4mm). The strips are mounted to specially designed mounting brackets. Typical application of strip curtains is in

cold/freezer room doors, factory entrances, partitioning, and spraybooths. Maxiflex Protection Screens protect personnel from sparks, splashes and welding flash. Formulated from a blue/bronze PVC that removes 99.9% UV in welding applications ensures optical safety to people not directly involved in operation. Excellent two-way vision through the near transparent strips allows for maximum visibility needed for safety and supervisory reasons. The Maxiflex Swingflex Door is a flexible impact door. it is perfect for enclosing doorways where traffic flow is of utmost importance. Medium-duty doors open with a gentle push and close automatically, ensuring a constant environment by reducing draughts, noise levels and preventing heat/cold loss. Enquiry No: 29

July / August 2014

EC Industrial & Business News

AUTOMOTIVE INDUSTRY

Local production S plant takes Silver T he J.D. Power Initial Quality Study (IQS) has placed the MBSA plant in East London amongst the top motor manufacturers in 2014, according to their poll of American consumers after 90 days of ownership of new models in this market. The MBSA plant has received a silver commendation in the Europe-Africa manufacturing region from this esteemed organisation, whose IQS quality rating is upheld by many in the international automotive industry as a benchmark for quality and reliability. As the only African plant on the list of awardees, this is the sixth consecutive award for Daimler AG’s South African plant. The company’s J.D. Power award collection now boasts two gold awards (2009 and 2011) and three silver awards (2012, 2013 and 2014) in the Europe-Africa region, as well as the ultimate accolade - a platinum award in 2010, as the highest ranking plant in the world supplying the American market. MBSA CEO and vice president of manufacturing, Arno van der Merwe, attributes the consistency of the manufacturing plant’s performance to a focus on efficiency improvement and stringent quality systems within the production process. “While technology and process excellence is of vital importance, equally essential is the mind-set and passion of our employees,” van der Merwe says. “We prioritise problem-solving at all levels within the plant, by harnessing the unique skills of our employees. This award is a tribute to their tenacity and expertise.” The East London plant produced the W204 C-Class for both the local and US markets, and registered only 27 problems per 100 vehicles (27PP100) surveyed by J.D. Power in 2014. The gold award recipient in the EuropeAfrica category performed only one point better, at 26PP100 vehicles. “This clearly shows the necessity to run a tight ship at our plant in

terms of reliability, efficiency and quality,” van der Merwe adds. The W204 C-Class model has been replaced by the latest model variant from Daimler AG, and started production at the East London plant in May 2014. “The fact that we have maintained the quality of our production in a run-out year, while simultaneously preparing both facility and employees for a new and more advanced model, proves the level of focus of our employees,” van der Merwe concludes. “We are extremely proud of this award and its implication for our status as a first-class manufacturer.” As one of only four Daimler AG plants world-wide selected to produce the luxury new C-Class, MBSA has invested in excess of R5 billion into the South African economy between 2011 and 2015. Close to R60 million has been channelled into training initiatives, with more than 1 200 training interventions and assignments to various international plants. In addition, nearly 900 unemployed people from the Border Kei region of the Eastern Cape have been upskilled as part of the new C-Class Enquiry No: 30 training programme.

Promoting Robotics and CodeSys training

esto Didactic is a global market leader in basic and further training in industry. Keeping the productivity of customer top of mind is achieved through continually adding new technologies to the list of topics that they train and by updating the courses available to the local market. Some of the latest courses from Didactic include Robotics and the PLC programming software, CoDeSys. “The use of robotics is increasing as more companies automate their production lines, from pick and place systems to high-speed applications” explains Festo Didactic manager, Horst Weinert. “As global sponsors of the Worldskills disciplines, Mechatronics and Mobile Robotics, we have considerable experience in bringing this technology to students. The Worldskills competitions make use of the Festo Robotino, a mobile robot system which participants need

to programme in order to complete a number of set tasks; and the MPS Modular Production Systems, with stationery 6-axis industrial robots. To support this technology locally, we decided to include robotics in our 2014 training portfolio.” “Furthermore, with the growth of embedded and PC-controlled industrial automation applications, we believe that it is becoming increasingly important to also teach different programming languages. We have therefore chosen to add a CoDeSys course to our range as this is a tried and tested international software, independent of any specific hardware.” CoDeSys is developed by 3S-Smart Software Solutions in Germany. It is the leading, hardware-independent, IEC 61131-3 development system under Microsoft Windows for programming and creating controller and HMI applications. The software is used across a number of industries and includes factory, process, energy and embedded automation amongst others. “The broad range of applications for this software, together with the fact that Festo PLC’s are compatible, made it an obvious choice for us to include this software in our offering” says Weinert. As part of the promotional activities around the MERSETA accredited CoDeSys course from Didactic, each participant is given a free Festo CoDeSys PLC Starterkit, including power supply and software so that they can practise what they have learnt and grow confiEnquiry No: 31 dent in their skills.

outh Africa’s automotive manufacturing industry believes it must learn from the dramatic collapse of the Australian auto sector. National Association of Automotive Components and Allied Manufacturers of South Africa (NAACAM) Executive Director, Robert Houdet said the Australian industry’s collapse, which could trigger the loss of over 30 000 jobs would provide valuable insight for South African auto companies. Houdet said learning from the Australian and EU crisis would be unpacked to industry at South African Automotive Week, by global manufacturing doyen and advisor to Australia’s shattered automotive industry, Goran Roos, whom Houdet says is “arguably the most capable of sharing these lessons.” Roos will be a keynote speaker at the 2-day conference, which forms part of the South African Automotive Week Tradeshow at Gallagher Convention Centre on October 14 and 15. “There are many learnings that the South African industry has to contemplate and implement to ensure the sustainability of our own industry,’’ Houdet said. The shock announcement, within months, confirming the closures of Ford, GM Holden and Toyota in Australia by 2017, which is forcing manufacturers to re-invent themselves in order to stave off mass job losses, is one of the most talked about developments in recent manufacturing history. Roos, a Swedish-born, celebrated academic across the globe and the founder or co-founder of several companies in different countries has worked as a consultant in more than 50 countries as well as having served in management positions in several European and US-based corporations. Most recently he has been supporting the Australian Prime Minister’s Taskforce on Manufacturing in Australia.

Lessons from Down Under

‘’The Australian scenario and the EU crisis which has virtually overnight decimated component manufacturers’ traditional markets, hold telling messages and learnings for African manufacturers relating to competitiveness, input costs, strategic positioning and the importance of diversification,” says Houdet. Roos, the author of over 100 books, was named one of the 13 most influential thinkers for the 21st Century by the Spanish business journal “Direccion y Progreso” and was appointed “Manufacturing for the Future” Thinker in Residence by the South Australian Premier and member of the Australian Prime Minister’s Manufacturing Leaders Group last year. His speech titled “The future of manufacturing in Australia: Innovation and productivity” was named among the Top 10 most influential and interesting speeches by the Australian government. Economic modelling by the Productivity Commission of Australia has predicted that up to 39,000 jobs, mostly in Victoria and South Australia would be lost after the end of production by Ford, GM Holden and Toyota in the period 2016-17. This estimate comprises 11,120 direct jobs being lost at the car manufacturers, plus another 28,100 jobs in the car component supply chain. Enquiry No: 32

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July / August 2014

AUTOMOTIVE INDUSTRY

Upward pressure on new car price continues

he latest TransUnion Vehicle Pricing Index (VPI) revealed ongoing stagnation of used vehicle prices as new car price inflation roars ahead. This is indicative of the current tenuous state of the South African automotive industry. While the increase in new car prices had been largely anticipated given the volatility of the Rand, the decline – albeit small - in used car inflation was unexpected, according to Keith Dye, CEO of TransUnion Auto Information Solutions. The vehicle risk intelligence company publishes the VPI on a quarterly basis. TransUnion calculates the VPI from data it receives on monthly sales returns from thousands of dealers throughout the country, as well as vehicle financing registrations from all of the major banks and vehicle finance houses. After rising out of negative territory for the first time in more than a year to 0.83% in Q1 2014, used car inflation

dropped slightly to 0.58% in Q2. “This drop may seem insignificant, but it marks a worrying trend as the used industry struggles to make up lost ground,” Dye said. “Not only did the upward month-on-month price movement seen in the first quarter of 2014 reverse in Q2, used inflation appears to be on an accelerating downward trajectory once again.” At the same time, new vehicle inflation is moving rapidly in the other direction. It rose from 5.62% and 6.58% in the previous two quarters, to 7.01% in Q2 this year, staying ahead of the CPI for the seventh consecutive month. The last time new vehicle inflation consistently outstripped the CPI while used vehicle prices sagged was at the height of the 2008/2009 recession.

However, the good news for the used market is that the trend towards the purchasing of used rather than new vehicles, which emerged in the first quarter, appears to be continuing. After climbing to 1.53 used vehicles for every new passenger and light commercial vehicle financed in Q1, the ratio continued to move in favour of used cars in Q2 at 1.67 used vehicles being financed to one new vehicle. At the end of 2013 this ratio was at 1.25 to 1. “We anticipate that this trend will persist as new car prices continue to rise, albeit not as sharply as they have thus far this year. Used prices are likely to keep on drifting for the next few months”. “Meanwhile overall demand for new and used vehicles is set to remain sluggish for the foreseeable future given the fragile state of consumer credit health in South Africa as indicated by the latest TransUnion Consumer Credit Index (CCI). In addition, banks are likely to maintain their tight grip on credit extension in the wake of the credit amnesty, making it even more difficult for consumers to purchase big ticket items like vehicles,” Dye conEnquiry No: 33 cluded.

VacPac - original moisture-resistant packaging.

EC Industrial & Business News

3-Millionth engine

he three-millionth engine, recently came off the line to great fanfare at Ford’s Struandale Engine Plant. Employees, media and officials cheered when the 3,2 litre, fivecylinder Duratorq TDCi engine - destined to power a Ford Ranger - joined the long line of high quality engines that have been produced at Ford’s Port Elizabeth facility, since it opened in 1964. “The engines produced here, just as the people who produce them, are world class and have helped power Ford’s success in Africa and around the world,” said Jim Benintende, president of Ford Middle East and Africa, who is in South Africa to celebrate the engine and Ford’s Go Further event. “Ford has a long term commitment to South Africa. We are proud to serve our customers here with a full family of high quality, safe and fuel efficient vehicles. We are also very proud of our highly motivated and world class workforce. Every day they demonstrate a commitment to Ford’s philosophy of continuous improvement with every vehicle that comes off the line,” added Benintende.

“This is a fantastic achievement for the Struandale Engine Plant,” said plant manager Satya Banda. “We can be especially proud of the work our local team has done to position the Struandale Engine Plant as a centre of excellence, exporting not only to Asia and South America, but now also to North America for the first time in our history.” The Struandale Engine Plant employs approximately 600 people, and received a major boost in 2010 when it was awarded the export contract to machine components and assemble high-tech Duratorq TDCi engines for the Ford Ranger. Over R3,4-billion was invested in the Struandale Engine Plant and the Silverton Assembly Plant in Pretoria, which produces the Ranger for the South African market, and for export to over 148 markets around the world. The crucial investment at the Port Elizabeth facility expanded the annual capacity of machined components at the plant to 220 000 component kits, comprising the cylinder head, block and Enquiry No: 34 crankshaft.

Safety screens for welding and grinding

pex Welding and Safety Screens have significantly contributed to improved safety in many manufacturing facilities throughout southern Africa. This innovative, locally manufactured p.v.c. screening material is most often used to cordon off welding and grinding bays. The specially formulated material used for Apex Welding and Safety Screens incorporates a heavy duty ultra violet light absorber that ensures dangerous u.v. radiation is safely contained in the curtained off area, protecting workers in the close vicinity. Apex Welding and Safety Screens are also impervious to burning, and this is of particular importance should the material come into contact with welding splatter. Although the Apex Welding and Safety Screens effectively close off the welding and grinding areas, the patented Balledge design on the individual strips facilitates easy access both for

personnel and equipment. Extensive tests conducted by the SABS proved the Apex Welding and Safety Screen material is superior to conventional material used for these products. Tested for ultra-violet transmittance, the conventional material gave readings of 0,005%, 0,008% and 5.0% as opposed to the Apex readings of 0,005%, 0,001 and 0,005%. When tested for total visible light transmittance, the tests were conclusive - the conventional material allowed 78 % while the Apex material allowed only 15,5% light transmittance. Enquiry No: 35

Ideal HMI alternative

mron’s feature-rich and cost effective NB HMI (Human Machine Interfaces) series is perfect for any industry requiring a small, affordable basic HMI touch screen. Offering the best in reliability, the NB HMI series is abundant in offerings and related benefits. “Often customers require more from an HMI in terms of the rudimentary offering, the LCD quality or the minimum approval requirements, and this is where Omron’s NS HMI series comes in as a fantastic alternative,” says Victor Marques, Country General Manager, Omron Electronics South Africa. “For example, the NB HMI series is the ideal replacement for existing monochrome units,” says Marques. “In addition, the replacement is easy to do as the cutout size is the same.” Replacements coincide with existing product as follows:

• Electrodes always factory fresh and dry - no re-baking required • Cost saving through simplified storage and handling • Reduced risk of hydrogen cracking and porosity ESAB Africa Cutting & Welding (Pty) Ltd 53 lake Road, Longmeadow Business Estate, North Gate, Edenvale Tel: +27 11 608 8200 Fax: 086 714 1354 E-mail: sales@esab.co.za Web: www.esab.co.za

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• NB7W can replace Easyview/ Weintek MT6056i/MT6070iH • NB5Q can replace Delta DOP-B05 • NB3Q can replace Pro-Face ST400 and NQ3 • NB5Q can replace NT31(C) using NB5Q-ATT01 mounting bracket The NB HMI series is characterized by best in class display with more than 65 000 display colours and a wide viewing angle across a 7 and 10 inch wide screen (resolution 800 x 480). In addition, a long-life LED backlight TFT LCD and 28 MB internal memory, offers customers outstanding solutions.

Enquiry No: 36

July / August 2014

EC Industrial & Business News

AUTOMOTIVE INDUSTRY

New paint technique reduces waste

olkswagen Group South Africa’s Paint Shop has introduced a ground breaking vehicle painting project which has become a benchmark in the entire Volkswagen Group production network. The project, which converts the painting technique to 100% electrostatic (called the Bell Bell process), has resulted in massive reduction in hazardous waste and led to a dramatic improvement in painting efficiency levels. “There are two different application processes - one for uni-base colours (for example red, white and black) and a second for metallic colours (for example silver or shadow blue),” explained Nico Serfontein,

Head of Paint Shop at the Volkswagen Manufacturing plant in Uitenhage . “The first application process employed in Base Coat Station 1 is used for all colours, uni-base and metallic and is referred to as an Esta or Bell application. The second, more conventional application process is used in Base Coat Station 2, where only metallic cars are painted for a second coat. This system works on the same principles as a manual spray gun, except that a double gun configuration is mounted at the end of a robot arm. It is referred to as a Spraymate System.” The main advantage of the Esta system is that it uses electrostatics to improve the transfer efficiency of the atomised paint, in other words 70% of the paint goes onto the car and the other 30% is disposed of as waste. The advantage of the Spraymate system is that it improves the colour appearance of the painted surface but unfortunately it only has a transfer efficiency of 35% with approximately 65% of the atomised paint going to waste. The Spraymate application technology was the only one available when the New Paint Shop was built in 2006 but since then, a new application system has been developed which not only uses electrostatics for improved transfer efficiency but also produces the desired paint surface quality. Uitenhage is the first Paint Shop in the Volkswagen Group to introduce the waterborne Bell Bell painting process – it has only ever been done on solvent-borne paint. Paint usage has been reduced by as much as 50% at the robot station, where modifications are made (currently using half a litre paint less than before). Less compressed air is also used, which results in increased energy efficiency.

With the Bell Bell painting process, the application is a lot softer. Therefore over spraying is lessened which results in fewer chemicals in the washout area. This in turn has lowered the Volatile Organic Compound emissions. “This advanced technology is in line with

the Volkswagen Group’s Think Blue.Factory strategy, which aims to reduce the environmental impact by 25% per car produced,” said Volkswagen Group South Africa’s MD, David Powels. Enquiry No: 37

Quality steering boot kits

KF recently extended its comprehensive driveline range to the automotive industry with a new complete range of OE quality steering boot kits. SKF VSM (Vehicle Service Market) supplies the global car and commercial vehicle aftermarket with superior quality products and premium services including bearings, seals, lubrication, and many other critical components for a wide range of applications in engines, electronics, driveline and wheel-end systems. SKF is a leading OE supplier of steering components. The company produced 20 million steering column bearings and 2 million EPS (electric power assisted steering) bearings for column, pinion or rack applications in 2012. SKF steering components also include steer by wire. “It therefore makes perfect busi-

Advanced wiper technology

hampion Easyvision is the rebranded consolidation of two tried-and-trusted wiper blade ranges . FederalMogul Marketing Director Heath Stow says that a ‘retro-clip’ system allows flat blades to replace conventional blades, thereby ensuring that the Champion range covers 95 percent of local light and commercial vehicles. “Flat blades provide a more uniform contact with windscreens, with evenly distributed pressure along the length of the wiper, thanks to variable geometry spoiler (VGS) technology, which responds to changing wind force to maintain a constant wiping performance,” he explains. An added benefit of this rebranded range is that two new flat blade designs have been introduced to allow the replacement of conventional blades through a patented ‘Multi Clip’ system, which connects seven popular wiper arms. “The Champion Easyvision flat blade wipers only use 15 references, in order to ensure that the range covers 95 percent of vehicles on the road.” Although flat blade wipers are more effective, they are also more costly, and Stow points out that Federal-Mogul has enhanced the design of the Champion Easyvision conventional blade range to offer motorists a more cost effective, yet highly reliable alternative.

Enquiry No: 39

ness sense for SKF to also supply OE quality steering boots,” says Gary Czapski who heads up SKF South Africa’s Automotive Division (VSM).” The new OE steering boot offering from SKF comprises more than 200 kits and covers a wide car parc which includes both European and Asian car models. In line with OE content, SKF steering boots a r e manufactured from rubber or thermoplastic depending on OE specifications. “We only supply specific metal clamps for thermoplastic boots as these are much more durable compared to plastic clamps supplied by some manufacturers.” SKF also supplies two universal steering boot kits which cover most passenger cars and Enquiry No: 38 light commercial vehicles. “ 71794 Tectra Automation Ad(Path).indd 1

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July / August 2014

EC Industrial & Business News

PLASTICS & RUBBER

Avoiding mechanical melt-downs

n tough economic times, mechanical engineers can be hard-pressed to extract the maximum lifespan out of plant equipment, especially where they have access to only limited budgets. In instances where machines are subjected to severe vibration, impacts or wear, it often pays to investigate the use of different rubber compounds that are increasingly being used instead of expensive mechanical parts. In many instances these rubber components perform equally or better than original equipment components. Engineered rubber specialists, Tega Industries South Africa, have been designing and manufacturing mechanical rubber solutions for different types of machines for decades. Depending on the requirements, solutions range from rubber shock absorption for anything from giant crushers, to mechani-

cal presses and even trains, while wear and tear protection is available in the form of linings and other protective devices. Speciality pipes, bellows and protection devices are also available to assist anything from cooling, to dust extraction and many more commonplace maintenance issues. According to the company’s business development and marketing

manager, Vishal Gautam, modern rubber compounds can be used for a wide variety of applications in the harshest environments. He advises engineers and maintenance personnel to investigate rubber solutions as a cost effective means to protect and enhance the performance of mechanical equipment. “Tega Industries is unique in South Africa in our ability to find engineered rubber solutions to a wide variety of mechanical problems. Our team of mechanical and rubber experts are able to work with customers and even undertake studies of equipment in need of protection and tailor make solutions to meet their requirements. “We have the ability to design and manufacture custom-made rubber and combination material products using our global expertise that enables polymer scientists and engineers from around the world to interface with our local experts to find solutions that meet African requirements. Our team of engineering experts are also ready to assist anywhere on the continent, wherever industrial plants are being expanded or maintained. Enquiry No: 40

“Zero plastics to landfill by 2030”

he South African plastics industry has set itself the ambitious target of eliminating all plastic from the country’s landfill sites by the year 2030. According to Plastics|SA, the umbrella body representing the entire local plastics industry, a new sustainability objective has been set under the title, ‘Zero plastics to landfill by 2030’, which will greatly influence the plastic industry’s strategic direction over the next 16 years. “Increasingly scarce natural resources and expensive landfill space has pushed recycling to the top of the agenda for all the packaging streams. The plastics industry is leading the charge by setting higher than expected recycling targets and getting industry role-players and government to agree on a combined plan of action,” says Anton Hanekom, Executive Director of Plastics SA. Plastics SA’s Sustainability Council, which comprises various polymer associations, such as PETCO, POLYCO, PSPC, SAVA and the SA Plastics Recycling Organisation (SAPRO) as well as major retailers and industry leaders attended a strategic workshop earlier this year, aimed at developing a united vision and road map for the future of plastic waste in South Africa. At this meeting, the Sustainability Council members voluntarily agreed and committed their organisations to working towards a vision of ‘Zero plastics to landfill by 2030’. While the plastics industry aims to use this target to drive the maximum value of plastics, it also hopes to enhance its reputation in the eyes of key stakeholders. “One of our main objectives is to enhance plastics recycling in South Africa on all levels through an active and ongoing engagement with key stakeholders such as national, provincial and local

governmental departments with regards to waste management legislation, regulations and the recent development of the industry Paper and Packaging Industry Waste Management Plan,” Hankom says. “Access to the solid waste stream is essential if we are to succeed in meeting our target, and therefore we are calling for ‘separation at source’ in order to increase the recycling rate of plastics”. Seven key areas of improvement and development were identified in order to align the plastics industry’s objectives with the targets set out by the Government’s National Development Plan. These include: • Developing an effective infrastructure across the value chain • Ensuring ongoing research and development into new technologies and markets • Establishing credible data sources and information sharing across the value chain • Developing skills to enable the technology and infrastructure • Changing and improving consumer understanding and behaviour around recycling and waste disposal • Developing industry collaboration towards the vision • Ensuring constructive and effective engagement and collaboration between industry and government Addressing the shortcomings and developing each of these focus areas will take place through a set of reachable objectives within the short term (foundation setting), medium term (building and innovation) and long term (optimising): Where recycling is not possible or difficult, industry leaders have also given their support to use plastics for energy recovery. Enquiry No: 41

Pipes viii conference

he Southern African Plastic Pipe Manufacturers Association (SAPPMA) has announced the main sponsors and keynote speaker for this year’s Pipes VIII Conference that will take place on Tuesday, September 2, 2014 at the Bytes Conference Centre in Midrand. “The theme of this year’s event will be ‘Plastic Pipe in Infrastructure’ and we have invited papers around this theme to look at the challenges and opportunities facing the industry, as well as the trends that influence the direction our industry is taking on a local and global scale,” says Jan Venter, Chairman of SAPPMA. Protea Polymers, DPI Plastics, Marley Pipe Systems and Fiberpipe have been confirmed as four main sponsors of this annual conference that attracts local and international experts involved in the manufacturing, installation and specification of plastic pipes, as well as the development of pipelines around the world. Economist and author of the

bestselling book, “The Long View”, JP Landman, has been invited as keynote speaker and will offer delegates a brief analysis of South Africa’s current and expected political-economic landscape, focusing on trends in politics, economics, demography and social capital. The organising committee is currently in the process of finalising the line-up of speakers for this year’s conference, and they are still expecting last minute submissions from presenters . Topics of presentations will range from plastic pipe failures, field pressure testing and pipe fittings to infrastructure, modelling of operating conditions for gravity and low pressure pipelines with factory tests. CPD points are available for professional engineers who are attending the conference, and SAPPA invites all interested parties to visit their website (www. sappma.co.za) to download registration forms or to obtain more information about the conference. Enquiry No: 42

July / August 2014

EC Industrial & Business News

WATER & EFFLUENT MANAGEMENT

Areas of Buffalo City now free to grow

Gonubie areas until its capacity could be upgraded. The project – completed recently by SRK Consulting (SA) – was carried out in two phases; the first phase was from 2007 to 2010 and the second from 2011 to 2014. SRK Consulting (SA) was responsible for the detailed design, tender documentation and adjudication as well as the construction monitoring and administration of the project. “In our 2005 report Testing of newly installed aerator system using to the municipaltreated effluent ity, we estimated the future loading of the esidential development in the treatment works and area of Quinera and Gonubie recommended that its capacity be in the Buffalo City Metropolitan upgraded from six megalitres/day Municipality (BCMM) will now be able to 18 megalitres/day,” said Marinus to proceed, following the expansion Meiring, principal engineering techof the Quinera Wastewater Treatment nologist at SRK Consulting’s (SA) Port Works near Gonubie in East London. Elizabeth office. “This is expected to The facility was nearing the lim- provide for future developments in the its of its installed capacity, and con- Quinera and Gonubie areas for the cerns about the possible overloading next 15 years.” of the wastewater works resulted in The upgrading project included a BCMM placing a moratorium on any number of innovations that will connew developments in the Quinera and tribute to the effectiveness and the

cost-efficiency of the treatment works, according to Meiring. “The use of a fine bubble aeration system was a ‘first’ for BCMM and, to our knowledge, also the first in the Eastern Cape at this scale,” he said. “It was chosen mainly to optimise energy use, as it can transfer 1,8 kg of oxygen per kWh into the sewage undergoing treatment – compared to the 1,1 kg capacity of the original surface aerators installed there.” The new treatment works adopts the mechanical dewatering of sludge, which requires a much smaller footprint to that of sludge lagoons or drying beds – and there is less risk of seepage into groundwater. “The plant itself is now also considerably more modern, employing a high level of automation such as inline analytical monitoring equipment in the final effluent to assess the realtime performance of the plant,” said Meiring. “New installations include SCADA systems and real-time process control to vary the oxygen input to the reactors when required – making the treatment more effective.” Another addition has been an onsite laboratory, where the process controllers can carry out basic analytical procedures to check the operation of the works and make adjustments where necessary.

Two new thermal imagers

omtest, Fluke’s local representative, has announced the addition of two new models to the Ti100 family of thermal imagers; the Ti90 and Ti95. These offer ‘best-in-class’ (up to 84% better spatial resolution and up to a 32% larger screen than others on offer), while using the same rugged - durable enough to handle a 2-meter drop - ergonomic form factor as the Tixxx series. For the latest in wireless technology, the T190 & Ti95 are loaded with the Fluke Connect app and an 8Gb wireless SD card, allowing users to share data in-field to get authorisations and complete orders without having to return to the office.

Additional SIPs will be designated by notice in the Government Gazette. To achieve its aim of improving, facilitating and coordinating public infrastructure development, the Act prescribes periods of time within which various stages in the infrastructure development process must occur. The Act is peremptory in this regard, noting that timeframes may not be exceeded. The period of time allowed by the Act for conducting public consultation on a project application and project plan is 30 days. The period for submitting a detailed development and mitigation plan (based on the project plan) to the relevant authority is 60 days. The instigator of a project then has 44 days within which to publically consult on the development and mitigation plans. The relevant authority has 57 days to assess and consider the development and mitigation plan and make a final regulatory decision. Timeframes for completing any of the stages involving public consultation may be extended upon written

Enquiry No: 45

Enquiry No: 43

Infrastructure development act comes into effect

n 10 July 2014, President Jacob Zuma made the proclamation which officially brought into force the Infrastructure Development Act, No 23 of 2014 (Act). The intention of the Act is to fasttrack infrastructure delivery in specifically designated areas. The Act recognises 18 Strategic Integrated Projects (SIPs) targeted for these fast-tracking purposes. These include: • SIP 8: Green energy in support of the South African economy; • SIP 10: Electricity transmission and distribution for all; • SIP 12: Revitalisation of public hospitals and other health facilities; • SIP 13: National school build programme; and • SIP 18: Water and sanitation infrastructure. The Act establishes the Presidential Infrastructure Co-ordinating Commission (PICC), and its Council, which is responsible for designating further SIPs, when this becomes necessary.

The Ti90 and Ti95 feature: • 5.6 mRad — Best-in-class spatial resolution; • IR-Fusion Picture-in-Picture; • 80x80 (Ti95) or 80x60 (Ti90) thermal resolution • Large 3.5 inch LCD & removable storage (8GB SD memory card) • IP54-rated Fluke’s Ti90 & Ti95 have been specifically designed with maintenance professionals, troubleshooting technicians, industrial and commercial electricians, HVAC/R technicians and facilities managers. government buildings, schools, hospitals and electrical and water utilities.

request. The Act also allows the PICC to expropriate land for the purposes of implementing a SIP. The PICC is required, before making an expropriation, to consult with the organ of state in whose favour the expropriation is made. This expropriation power remains a point of contention in this Act, since it remains unclear how it will interact with the Expropriation Act, No 63 of 1975. Finally, to achieve its goals, the Act creates Steering Committees. These Committees are tasked with providing concrete assistance to the SIPs, by identifying necessary authorisations, licences and permissions for a project, instructing that these be submitted simultaneously, and ensuring applications for these consents are complete, compliant and their progress is monitored.

SPP Pumps (South Africa) (Pty) Ltd are authorized distributors of the Global Sterling Fluid Systems Group originally founded in 1895. Our experience spans all pumps and associated parts, but is not limited to those designed and manufactured by SPP and Sterling Fluid Systems. The extensive SPP, SiHi, Halberg and LaBour range of specialist pumps is a prime example of the extent of our capability.

JHB / Head office: 011 393 7181/2 ph@spppumps.co.za www.spppumps.com

Specializing in : Unistream, Thrustream, Eurostream, Aquastream and Instream pumps supply, spares and service. Also including fire prevention sets.

PE Branch:

KZN Branch:

CT Branch:

041 364 0204 ft@spppumps.co.za

031 700 3773 ng@spppumps.co.za

021 852 3962 rh@spppumps.co.za

The article was written by Samantha Brener, Candidate Attorney, and verified by Claire Barclay, Director, Projects & Infrastructure, Cliffe Dekker Hofmeyr Enquiry No: 44

SPECIALISTS IN

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July / August 2014

WATER & EFFLUENT MANAGEMENT

EC Industrial & Business News

Going the extra mile

N July, SBS Tanks supplied and installed a ST09/02, 63 Kiloliter capacity water tank, in the Ngcobo community in the Eastern Cape. The project, Cluster 6 Ngcobo Water Supply, initiated by the Chris Hani District Municipality is aimed at providing water for the local community. Although the tank is not yet commissioned, the installation is complete and the tank stands ready for filling. Mzolisi Gwagwa, Lead Installer for the project, explains the challenges of this installation, “the site was situated on the side of a mountain which made is difficult to transport the body of the tank by vehicle directly to the site. To overcome this challenge we made use of 4

community casuals who assisted us in carrying the parts to the site by hand.” This is just one example of SBS Tanks going the extra mile to meet their customer requirements. SBS Tanks is a Proudly South African and ISO 9001:2008 certified company based in Pinetown, KwaZulu-Natal. They are the leading supplier in the manufacture and installation of premium quality Zincalume panel liquid storage tanks. With a strong work force of 56 permanent employees, SBS is big enough to deliver, yet small enough to care.

Enquiry No: 46

Submersible slurry pump

he KBS submersible slurry pumps from Raptech are rugged in design and have the ability to pump both the corrosive and/or abrasive slurries found in the mining and process industries. The pumps have a four-pole motor for an increased lifetime and agitator designed to handle tough applications. Since water always flows to the path of least resistance, a pump without mechanical agitation will only pump the water, leaving the solids behind to accumulate around the pump intake, and eventually starving the pump by blocking the intake. Agitator

pumps deliver kinetic energy (energy of motion) to slurry solids surrounding the pump intake, re-suspending them into a fluid state. These solids, which would have otherwise buried and starved the pump of liquid, are pulled into the pump and pushed on through the discharge keeping the intake clear and free of slurry accumulation.

Honoured at the SIPEC trade fair

L The completed SBS Tank in the Ngcobo community The KBS pumps have a slim design with a top discharge enabling installation in smaller casings and they are suitable for bentonite mixed water in foundation works or muddy water in civil engineering works. They are also suited for applications in quarries, slurries and general pumping applications. With a capacity up to 3.25m3/ min and heads up to 22 m, the pumps have an 80 mm to 150 mm discharge and operate in a 4 kW to 9 kW range. Meeting insulation class F, the submersible slurry pumps are suitable for use in water temperatures up to 40°C and in water depths up to 30 m. Enquiry No: 47

ast year at the SIPEC trade fair in Orléans (France), the Innovation Prize went to GEMÜ for the development of its innovative GEMÜ 650TL “safety valve”. If the flow velocity in a loop reduces, it can fall below a critical value. When the GEMÜ 650TL diaphragm valve is used, selected tapping points can automatically be closed by the central process monitoring system in order to reduce the tapping quantity and thus increase the flow velocity. It is now also possible to query the position of the handwheel. In this case, the position “handwheel closed” is detected by an optionally available proximity switch and communicated to the plant control system. Previously, this was only possible for the piston position of the actuator. Due to this improvement, a visual check of the plant in person is no longer absolutely essential. The position “handwheel closed” can be checked simply and conveniently from the control room. The GEMÜ 650TL contributes to protecting plant operators and the conducted medium, Enquiry No: 48 even if the valve closes.

Relay detects dry running conditions in pump applications

ewElec’s KE electronic motor protection relay is ideally suited to detect dry running conditions in pump applications. User-selectable dry run detection methods may be either by current or by power factor measurements. The relay detects dry run conditions on small kW motors and in applications where a large drive ratio is a factor, such as with V-belts or large reduction gearboxes. Nuisance load loss trips are avoided with ‘pump prime time settings’ and user-selectable trip time delays are all built-in.

The relay can be selected to automatically restart the motor after a given time interval (only on dry run trip conditions). Jam or running stall protection with userselected trip levels and trip delay times, start per hour limitation settings, permissible consecutive starts, short circuit protection and statistical motor operation data are provided. Phase rotation, over and under voltage measurements are all included features. The thermal overload curves are adjustable Class 5 to 40 s. Earth leakage and earth fault protection

features are available with appropriate and distinguishing latched LED fault displays. The trip sensitivity threshold can be set in the range 30 to 1 000 mA. The curve may be set for instantaneous (trip delay settings 100 ms to 1 s) or IDMT. Incorporated into this is harmonics filtering allowing for far less nuisance trips when used with VSDs or high inrush currents.

Even more protection is made available by adding the earth insulation lockout module that prevents starting of the motor when the windings are contaminated. The relay also measures real and apparent power motor consumption and logs up to 2 000 events and 60 last faults with accompanying current and voltage measurements at time Enquiry No: 49 of trip.

Geared Motors \ Drive Electronics \ Drive Automation \ Industrial Gears \ Services

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We drive the water industry

SEW-EURODRIVE, a BEE company, leaders in the field of geared motors are now able to supply an Industrial Gear Unit that offers more efficiency for mixing and agitating applications with their MC range of Extended Bearing Distance (EBD) Industrial Gear Units. In process plants, large axial and radial forces occur at the agitator shaft during agitating processes. Traditional designs solve this problem with separate, external bearings that take on the function of the agitator shaft bearings, a solution that very often proves cost intensive. Our new EBD concept extends the bearing span across the low speed shaft and offers stronger bearings within the gear unit itself, which means that in many cases separate bearings are no longer required in the agitator or an oversizing of the gear unit can be avoided. These high torque MC Industrial Gear Units can be used for the reliable operation of mixers, mounting flanges, agitators and surface aerators.

Welcome to the future – a future of Mwangaza We are all writing a part of the script which tomorrow’s society will play out.

At Royal HaskoningDHV we would like the title to read: ‘Welcome to the future’ -

Visit us at Electra Mining Nasrec Expo Centre Hall 6 Stand J 20 15-19 September 2014

and for our chapter in that script to read ‘Mwangaza’ - a Swahili word which means

‘light’. Together with our partners and clients we consider how we can create a welcoming future - developing efficient and smart living.

Whether switching on a light, travelling to work or drinking a clean glass of water - the solutions and work of our engineers surround us, making lives better and

brighter. Our work contributes to the sustainable development of communities. Together, we deliver innovative sustainable answers to today’s challenges.

SEW-EURODRIVE - Driving the world. Tel: +27 11 248-7000 Web: www.sew.co.za

Royal HaskoningDHV is an independent, international engineering and project management consultancy.

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July / August 2014

WATER & EFFLUENT MANAGEMENT

EC Industrial & Business News

Pipeline division on schedule The GRID is a graphic element that helps to create the ZEST indentity. Derivative of the proportions of the logo, it is based on a proportion of width and height of 2-to3. The distance between the GRID elements is 1/3 of the height of an element.

The GRID What is it?

eading civil engineering and construction group, Esor’s Pipeline Division, is on schedule to complete the installation of a 22,3 km DN600 cement mortar lined steel water pipeline from the Xonxa Dam to Queenstown Water Treatment Works. This project, awarded in November 2012 by the Chris Hani District Council, is part of the greater Xonxa Dam Transfer Scheme and Bulk Water Supply project initiated by the Chris Hani District Municipality in the Eastern Cape to augment the Queenstown bulk water supply. The project will address the current water supply shortfall within the municipality and open up an urgently needed supply of bulk potable water to indigent areas in and around Queenstown. Esor’s scope of work includes site clearance for the new pipeline, connections to the pump station delivery line intake and reservoir intake, as well as road and river crossings. The route for the pipeline includes two above ground/

surface sections. One is a 900 metre long concrete encased section traversing along the base of the hill opposite the Xonxa dam, with the other portion being only 100 metres in length but going over the mountainous rise. This 100 metre piece of the pipeline is to be supported on concrete plinths. The difference in elevation from the pump station to the top of the mountain section is 400 metres static. Ian Foord, Esor Pipeline Division’s site agent says, “This is our first project for the Chris Hani District Council and we’re delighted to be partnering with such a progressive and forward-thinking organisation on an important project like this.” Special environmental requirements on the project include the demarcating and ensuring the protection of two very old trees and preservation of a collection of Bushman paintings near the mountainous section as well as preservation of an ancient Bushman stone

tool factory. Stringent safety procedures have ensured that the project recorded more than 253 530 LTI-free hours by mid-March. Supplementing the Esor core pipeline project team of 30 skilled personnel, including operators, coded welders, foremen and supervisors, are 165 local labourers that have been recruited and trained in various facets of pipeline construction, where applicable. Esor’s pipeline division operates mainly in the gas and petrochemical, water, stormwater and sewerage sectors. With specialist expertise in laying and welding of steel pipelines as well as in pipeline refurbishment including mechanical and linings and coatings, the division services both public and private sector clients from top mining and industrial groups to regional and municipal government. A fully equipped workshop and yard to support fleet maintenance operates onsite at the business unit’s head office. Enquiry No: 50

New metering pump for high accuracy use

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ollowing the highly successful launch of the revolutionary Qdos 30 peristaltic metering pump, Watson-Marlow Pumps Group is now introducing the larger Qdos 60 model. This innovative and versatile new pump is designed to save costs in chemical metering applications thanks to its inherent higher accuracy metering. The addition of Qdos 60 expands the range to incorporate flow rates from 0.1 to 1,000 ml/min (0.001 to 15 USGPH) at 7 bar (100psi). Furthermore, simple installation and easy, tool-free maintenance ensure total cost of ownership is minimised. With the market demanding cost effective systems offering low operational expenditure, Qdos 60 negates the need for ancillaries, boosts productivity and cuts chemical wastage via more accurate, linear and repeatable metering than conventional solenoid or stepper-driven diaphragm metering pumps. As a result, Qdos 60 is able to reduce chemical costs even when metering difficult fluids, or when pressure, viscosity and solids content vary. This capability combines with peristaltic technology to ensures precise, continuous smooth flow for optimal fluid mixing. Typical applications for Qdos 60 include disinfection, pH adjustment and flocculation of drinking water, wastewater and industrial process water, as well as reagent dosing/metering in mineral processing tasks. The new pump is especially suited to chemical metering applications found in larger water treatment plants where flow demand is greater than that provided by the existing Qdos 30 model. Advanced control features include fluid level monitoring, fluid recovery, line priming and intuitive flow calibration. Driven by ever-higher quality standards, enhanced pump accuracy enables higher concentration chemicals to be used, thus saving on transport costs and driving down carbon emissions targets. Installing Qdos 60 could not be simpler. This drop-in pump requires no pulsation dampener, strainers or float switches, nor does it require any de-gassing, back-pressure or foot valves. What’s more, the pump meets the demand for low/no upkeep products driven by reduced maintenance budgets. This is because there are no seals or valves in the Qdos 60 flow path to clog, leak or corrode, and there’s no opportunity for vapour lock. In addition, Watson-Marlow’s patented ReNu pumphead technology provides a single, safely contained component for rapid maintenance without the need for tools. Rapid, straightforward pumphead removal and replacement minimises process downtime and demands no specialist training or technicians. Ideal for installing in restricted environments or on skids, the pumphead can be configured on the left or right. Intuitive operation is facilitated via a menu-driven interface featuring a 3.5” TFT colour display with high visibility Enquiry No: 51 status indication.

July / August 2014

WATER & EFFLUENT MANAGEMENT

EC Industrial & Business News

Tough on jobs, easy on costs

ough jobs are no match for Xylem Water Solutions South Africa’s new range of Lowara e-NSC pumps. The new Lowara e-NSC heavy duty end suction pumps are designed to take on the most challenging water related problems at the lowest costs. By combining high efficiency with high flexibility in terms of installation, material options and temperature, the new Lowara e-NSC series is the natural choice for a vast number of Industrial and Building applications. The robust design, different bearing frame sizes and stainless steel replaceable wear-rings ensure a long service life. The Lowara e-NSC pump’s easy maintenance will also reduce downtime.

Constantly working towards a greener future, the new Lowara e-NSC series has been designed to offer end-users the most energyefficient solution possible. It has a Minimum Efficiency Index (MEI) well above the level required by the ErP Directive’s 2015 update – and uses IE3 motors, which require very low operation costs. This offers long-term economic benefits to clients. The ErP Ecodesign Directive 2009/2015/CE supports the sustainable and economic use of available energy resources. Its main goals are encouraging ecological design and fighting against climate change by reducing CO2 emissions to the atmosphere. When combined with Xylem Water

Solution South Africa’s Hydrovar pump controller, the Lowara e-NSC’s p u m p s p e e d can be reduced by 50% to save as much as 82.5% of power consumption, compared to a traditional pump. Given the scale of many commercial and industrial heating systems, this can significantly reduce a building’s energy costs without having an impact on system performance. In order to cater best for the

ever changing needs of the Industrial Building Services market, Lowara’s e-NSC end suction pump is available in six different sizes ranging from DN100 to DN300, and can reach pump flows of up to 1,800 m³/h. With a head of up to 120m the e-NSC series can perform to a maximum pressure of 16 bars and pump water ranging from -20°C to +140°C. An extended temperature version is also available which can transport water from -40°C up to +180°C. “With the electricity costs on the rise, our energy-saving e-NSC range can provide end-users an avenue to reduce these bills and improve the overall efficiency of their HVAC system. The new Lowara e-NSC series offer customers a long term econom-

ical pumping solution,” said Ernst Viljoen, Growth Centre Manager: Applied Water Systems at Xylem Water Solutions South Africa. As a leading provider of intelligent industrial pumps and related technologies, Xylem Water Solutions South Africa’s new Lowara e-NSC range also incorporates a number of innovative features. These include mechanical face seal options to eliminate leakages, which are available in different materials including the standard mechanical seal configuration (Silicon, Carbon, EPDM). Casing materials options range from cast iron to duplex stainless steel – to cater for any liquid which may need to be pumped. It is suitable for a variety of applications, including: water transport, hydronic heating and chiller systems and fire systems. Enquiry No: 52

Plastics industry’s efforts to combat marine litter up 90 %

P You are an expert in water treatment You want process reliability We have the solution for you

lastics SA has announced that there are currently approximately 185 projects planned, underway or completed as part of the Declaration of the Global Plastics Associations for Solutions on Marine Litter (Global Declaration), a public commitment by the global plastics industry to tackle plastic in the marine environment. The announcement came with the release of the international plastics industry’s annual progress report, which documents the projects underway around the world. “Plastics SA was one of the signatories of the Global Declaration, which was co-signed by leaders from plastics organizations across the globe in March 2011 at the 5th International Marine Debris Conference in Honolulu, Hawaii,” says Douw Steyn, Director: Sustainability at Plastics SA and Chairman of the Outreach and Stakeholder Engagement of the Global Action Team on Marine Debris (GAT). Since initiating the Global Declaration, signatories have identified numerous specific actions designed to fulfil these commitments

and have agreed to track and report progress. According to the 2013 report, the international plastics industry’s efforts boasts a 90 % increase in projects that combat marine debris . “It was encouraging to see 60 plastics associations from 34 countries across the globe voluntarily sign the declaration in recognition of the important role they have to play in fighting marine litter,” Steyn says, explaining that each of these associations launched and support projects in six key areas aimed at contributing to sustainable solutions. The six focus areas of the Global Declaration are education, research, public policy, sharing best practices, plastics recycling/recovery, and plastic pellet containment.” “This is a tremendous increase in participation, considering where we started,” says Steyn. “As an industry, we have an important role in contributing sustainable solutions for marine litter. To this end, Plastics SA hosted the first African Marine Debris Summit

last year, and is currently planning a second marine debris summit to take place in Cape Town in June 2015.” This umbrella body representing the South African plastics industry will also once again be coordinating the 29th International Coastal Clean Up day on Saturday, 20 September 2014 as part of its commitments to find tangible and workable solutions for the problem of marine litter found in South African oceans and around the continent. “Across the globe and in a remarkably short amount of time, we’ve seen a ramp up of programs that address marine debris, many of which involve cooperation with governments, non-governmental organizations, researchers, and other stakeholders. The cooperation between different stakeholders is crucial to tackle this very serious issue and we believe is the right path to follow,” Steyn concludes. Enquiry No: 53

Genuine service kits reduce technician time

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n a customer-focussed move to simplify repairs and maximise the life and performance of its products, the Gast Group – a leading designer and manufacturer of air handling equipment and member of IDEX Corporation’s health, science and safety division – is introducing a range of Preventative Maintenance & Service Kits and promoting the use of genuine GAST and JUN-AIR parts to reduce the hassle and maximise the impact of repair. To communicate the benefits of preventative maintenance and illustrate the procedures and components required to carry out regular servicing of its rotary vane

compressors, piston compressors and air motors ranges, the Gast Group has also produced complementary videos, which can be found on the Parts & Service section of the company’s website. As Gast Group’s service and support manager Malcolm Bruce explains, the company’s Preventative Maintenance & Service Kits can help to extend product life and avoid unplanned system or compressor downtime. “The benefits of using and stocking genuine kits are clear to see. A recent survey by our European customer service department revealed that technician time was reduced by up to 80% and unnecessary waiting

times and delays eliminated when comparing preventative maintenance servicing with unplanned repair.” Available for GAST and JUN-AIR products – including oil-less and oillubricated compressors, air and gear motors, vacuum generators, blowers and systems – the company’s Preventative Maintenance & Service Kits have been developed by Gast Group’s technical and service teams. Each kit contains genuine parts and simple instructions to ensure technicians and maintenance teams have everything required to complete the servicing of products and systems successfully. General Pneumatics is the local agent for Gast. To further simplify servicing and maintenance procedures, training videos are also available on the Gast Group website. Enquiry No: 54

Locally designed high pressure globe valves A leading innovator in manufacturing and process automation, Festo has been active for many years in the area of water treatment, with complete, single-source automation solutions tailored to meet the needs of plant operators. Whether for municipal or industrial water and wastewater treatment, Festo offers individual automation solutions that are powerful, economical and reliable.

Specialists in Corrosion Protection

08600 FESTO www.festo.co.za HotDip Galvanizing – 3m x 1.2m x 1.8m Thermal Zinc / Aluminum Metal Spraying

Protective Coatings and Linings Abrasive Blasting

Tel: 041 4511947 | Fax: 041 4510773 | Cell: 0824410692 E-Mail: henning@galvaspin.co.za | Website: www.galvaspin.co.za 2 - 5 Fearick Street, Sidwell, Port Elizabeth

itech has released details of its new locally designed and manufactured High Pressure Stop Globe Valves. The new valves feature the same robust, low maintenance design characteristics as the rest of the Mitech range of control valves. Designed to handle some of the industry’s most e x t r e m e high-pressure and high-temperature applications, the valves provide low cost and hassleEnquiry No: 55 free inline maintenance.

July / August 2014

EC Industrial & Business News

COEGA DEVELOPMENT ZONE

Putting an end to tough times T HE Coega Development Corporation’s (CDC) initiative to advance Small, Medium and Micro-sized Enterprises (SMME), has exceeded its annual participation goal creating job opportunities for many unemployed people in Nelson Mandela Bay. Coega’s SMME development has a target of 35% SMME participation on all contracts awarded and exceeded this, achieving 37.92% SMME involvement and participation during the 2013/2014 financial year. In 2013 Coega launched its R400 000 BEESIP (BEE Scorecard Improvement Programme) which assisted 100% blackowned and black women-owned enterprises to improve their B-BBEE status levels to achieve Level 1 thus improving their competitiveness during the tendering processes. Coega has already awarded 100 BEE certificates to local black SMMEs of which 65% were black female and 50% were youth entrepreneurs. “CDC has a fully-fledged Small Business Development (SMME) Unit that focuses on SMMEs capacitation and development. The Unit ensures that training sessions are conducted and mentorship programmes are completed by companies that are on site. “This is done to ensure that small companies are not exploited by the main contractor, but rather that they are fully developed. “The database is also refreshed to ensure that the information contained is credible and responsive to the needs of the main contractors,” said Andile Ntloko, CDC SMME Unit Head. “We want to ensure that black owned businesses thrive because this is one way of alleviating poverty and simultaneously creating employment opportunities.” “We ensure that we monitor compliance and possible exploitation by the main contractors, by actually physically being there and communicating with both parties. Our team of SMME Unit facilitators physically does weekly site visits to monitor the development of small contractors,” Ntloko said. “Within the region of Nelson Mandela Bay we currently have about 80 SMMEs that have benefited from CDC contracts, with an estimated contract value of R 50 million. In the entire Eastern Cape Province, 120 SMMEs have benefited with an estimated contract value of R 400 million,” said Dr Ayanda Vilakazi, CDC

head of marketing & communications. In total, 200 SMME’s are benefiting from Coega programmes, Dr Vilakazi added. Nelson Mandela Bay based small business, Siwela Inkoleko Joint Venture (JV), is not only benefitting from Coega’s SMME initiative, but is also creating job opportunities within their community. Siwela JV, a cleaning company, started by Thozama Grootboom and business partner Nocama Nondumo, both from Motherwell in Port Elizabeth, created work for 18 men and women who largely live in the impoverished Motherwell area. “A lot of people in Motherwell and

Wells Estate are unemployed. They are suffering. There are families who bought houses but because someone in that family was retrenched they lost their houses or are drowning in debt,” Grootboom said. Nondumo, a single mom of twin daughters, who gained experience in sub-contracting as a cleaner, working for other government entities, said it was “unbelievable” what peace of mind she has since signed up as an SMME with Coega. “Now with a steady income I can sleep at night for a change. I am a properly functioning person,” Nondumo said. Enquiry No: 56

JOB CREATION: Business partners, Nocawa Nondumo (left) and Thozama Grootboom founders of Siwela Inkoleko Joint Venture (JV) of Motherwell in Port Elizabeth created work for 18 unemployed people.

2016-19 for manganese relocation he manganese facility in the Port Elizabeth T Harbour will now only be relocated to the Coega Industrial Development Zone in 2019

and not 2015/6 as was envisaged earlier. The facility and tank farm will, however, still be relocated, Transnet National Ports Authority (TNPA) Chief Planner Nimi Ramchand said recently. Addressing a TNPA briefing on the latest updated Port Development Framework Plan Ramchand said TNPA was “a couple of years behind unfortunately”. She said one of the reasons for this was that it was a “mega-project” that also involved the upgrading of the whole network linking the Port of Ngqura and the Coega IDZ with the Northern Cape for the transportation of the manganese. Ramchand said the development involved a “huge investment so we have to be extremely cautious about what we are investing in”. She said the first manganese exports from the Port of Ngqura were expected to take place early in 2019 “when the decommissioning of the Port Elizabeth facility will get underway”. Earlier, TNPA Senior Manager Capacity Building Desmond Simpson said that the third container berth at Ngqura was currently being equipped, adding that the port would have a capacity of two million twenty-foot equivalent containers a year. Simpson stressed that what was done at the ports of Ngqura and Port Elizabeth had to be done within the context of Nelson Mandela Bay adding: “our task is to create jobs and not destroy them”. He explained that the manganese would be exported from two berths with a capacity to export between 22 and 25 million tons a year. Two scenarios had been drawn up with regard to Project Mthombo, the oil refinery planned for the Coega IDZ. One was based on permission being granted for construction of a pipe-line from Coega to Gauteng and the other for the refined product to be shipped to Enquiry No: 57 Durban.

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2012/12/05 11:32 AM

July / August 2014

COEGA DEVELOPMENT ZONE

EC Industrial & Business News

Coega partnership opens Chinese investor corridor

EADING Chinese automotive manufacturer First Automotive Works (FAW), has launched its R600-million assembly plant in Zone 2 of the Coega Development Corporation’s (CDC) Industrial Development Zone (IDZ) recently and the plant was opened by President Jacob Zuma. FAW’s decision to build the plant in South Africa is significant as it is one of the biggest manufacturing investments by a Chinese entity in the country to date, with tangible spin-offs. It is the result of a presidential visit to China in 2007 led by President Jacob Zuma and was brought to fruition by the unfailing support of various departments of the South African government such as the Department of Trade and Industry, National Treasury, International Relations and Cooperation and many others. Speaking at the opening of the facility, President Zuma said: “The investment of R600 million into the economy will create much

needed jobs and promote an improvement in the lives of many people in this area. “ “This investment also augurs well for South Africa’s position within the global automotive manufacturing network and proves once again that we have an attractive operating environment to host global multinational companies.” In particular, it has created Chinese investor confidence in South Africa, inspiring further Chinese investments in the country. Chinese manufacturers Powerway Engineering (R127million) and Powerway Photo Voltaic (R666.6million) have confirmed their investments in the IDZ and will commence operations very soon, bringing the total sum of Chinese investment in the IDZ to R1.394 billion. Yusheng Zhang, CEO of FAW Vehicle Manufacturers SA (PTY) LTD said the decision in 2012 to construct the local FAW plant, was not taken lightly. Other African countries were considered for

Accelerated and Shared Growth Initiative South Africa (AsgiSA), applicable SETA's and the private sector. "The Coega Skills and Training Development Centre is deeply grateful to Ford for their generous and relevant investment in the skills development of our labour market," said Dr. Ayanda Vilakazi, Coega Development Corporation's marketing and communication manager. "The donation of these engines will undoubtedly support technical and vocational skills development of emerging talent. This, in turn, will have many positive spinoffs on employment and poverty eradication, which support a wider set of critically strategic socioeconomic goals. "Coega will continue to provide training on critical skills needed by the market. As a result, it is vital for the private and public sectors to continue working closely, cooperatively and persistently to address and improve skills development in the Nelson Mandela Bay Metro and the Eastern Cape at large. This will ensure that labour in the automotive manufacturing value chain remains productive and globally competitive," said Dr. Vilakazi.

Engines donated towards training

the new location however South Africa’s infrastructure development was highly attractive. “We could have gone to Kenya, or Tanzania where FAW has been present in sales and service for over 30 years – but in the end we chose South Africa because of the infrastructure. It then came down to a choice between East London and Coega.” In the end Coega was chosen because, according to Zhang “the infrastructure is perfect”. Phase one of the FAW project is expected to produce 5 000 trucks annually and 280 jobs will be created during the truck assembling

plant’s operational phase. A possible second phase of the project, which will see an additional investment from FAW, is expected to produce an additional 30 000 light commercial and passenger vehicles annually.

Gas investment lights up economy

and development

he Ford Struandale Engine Plant (SEP) recently donated two of its 3,2-litre, fivecylinder Duratorq TDCi and two of its 3,2-litre, four-cylinder Duratorq TDCi engines to the Coega Skills and Training Development Centre. "Coega's training services aim to address skills development and job creation in the Coega IDZ, the Nelson Mandela Bay Metro and the Eastern Cape at large. As one of the largest manufacturers in the province, job creation and skills development is one of our biggest objectives too," says plant manager Satya Banda. Coega Industrial Zone offers skills development through training programmes that focus on assessor, moderator, coaching and facilitation training; basic construction skills; safety and supervisory training; and apprenticeship implementation in the construction and mechanical trades. Coega sources funding for its training programmes through the Department of Labour,

Enquiry No: 59

Enquiry No: 58

LOBAL industrial gas leader Air Products is making an impact in the Eastern Cape and creating employment and business opportunities alongside economic advantages for local industry with its R300-million investment in the province’s first air separation unit (ASU). Construction and installation of the plant in the Coega Industrial Development Zone (IDZ) will have created approximately 120 jobs by the time it is commissioned in the fourth quarter of 2014, said Air Products onsite project manager Robert du Pisanie. The new plant will supply industrial gases, in particular oxygen and nitrogen, to Air Products’ established Eastern Cape customer base. It will also open up opportunities for entry

into new markets with a series of new prospective clients showing increased interest in the company’s expanded – and more affordable – offering locally. The first of its kind in the province, the ASU will bring security of supply to industry that previously relied on gas being trucked cross-country by road. It will produce 110 tons of liquid nitrogen and oxygen per day and has been built with the capacity to scale-up production to meet market demand. The project has also created opportunities for local small and medium enterprises (SMEs), consultants and contractors. Du Pisanie said the civil works were “100% implemented by Eastern Cape contractors”, with the lion’s share of the engineering and design work also done by local consultants.

He added the company was committed to pushing as much as possible of the Air Products investment into the Eastern Cape. “An air separation unit is a highly specialised, technical operation and, out of necessity, most of the components have to be imported. However, in terms of construction materials, we have sourced a significant proportion from Eastern Cape suppliers,” he said. In addition to employment created during construction and the electrical and mechanical installation phases, the plant itself will employ between 10 and 15 people once operational. “The significant impact however is in the local and regional value chains where security of supply and the support of our world-class technologies enabling customers to improve processes and competitiveness, will unlock business opportunities and support employment,” Air Products managing director Mike Hellyar said. He said Air Products had made a strategic decision to locate an air separation unit in the Coega IDZ based on promising economic and industrial growth in the Eastern Cape, particularly the pipeline for mega-projects at Coega, and growing demand for industrial gases in diverse sectors from automotive to agro-processing, food and beverage, renewable energy and pharmaceuticals. The project is well on track for completion in the fourth quarter of this year, with gas set to flow to customers before the end of 2014. Enquiry No: 60

Online shop makes products readily available

n the digital age of business, the need for online shopping has rapidly evolved from the commercial consumer sector to the industrial sector too. Sub-Saharan African gas market leader Afrox has identified this trend through the establishment of its eShop. Afrox customer service centre selfservice manager Brett Sauerman explains that 96 percent of the entire Afrox range is available via the eShop, with the exception of bulk gas orders (tank) and other made-to-order products. “The eShop provides an alternative online channel to market, and is a value-added service for numerous customers.” The Afrox eShop is divided into two sections, namely; the ‘web shop’ – a catalogue-based facility that features all Afrox products that are available online; and ‘self-service’ – a function that enables customers to manage their own transactions using online account management features. Sauerman indicates that Afrox first identified the need for an online store in early 2013 in response to the growing global trend of streamlining the purchase and supply process.

“As a result, we launched a pilot programme with around 40 customers in April 2014. The objective was to test the system from a technical perspective and to test our supporting business processes,” he explains. Following the success of the pilot, the eShop was officially launched in June 2014, and the response from customers has been overwhelmingly positive. “Customers have informed us that they are particularly pleased with the ease-of-use, as well as the professionalism that is applied from start to finish throughout all the services offered via the Afrox eShop.”

The availability of products online is determined by customer demands, and is therefore continually updated. “All products ordered via the eShop are delivered onsite, although the option for depot collection will be readily available within the next few months.” As the eShop is still in its infancy, Afrox is committed to expanding its service offering and functionality. “The online service is currently limited to South Africa; however, there is a possibility of making the service available internationally.” By late 2014, customers will be able to open an Afrox eShop base account in under five minutes and, for added convenience, download a free mobile application service. Afrox customers have access to the eShop support team on a 24/7 basis, 365 days a year. Products available at the Afrox eShop include; industrial gases, LPG (Handigas), gas equipment, Arc equipment, Arc accessories, welding consumables, abrasives, industrial chemicals and personal protection equipment (PPE). Enquiry No: 61

July / August 2014

EC Industrial & Business News

COMPANY & PRODUCT NEWS

Baywest Mall construction

he Chryso Southern Africa Group is supplying a wide variety of essential products for the construction of the R2 billion Baywest Mall, which will, on completion in Port Elizabeth next year, become the biggest mixed-use precinct in the Eastern Cape, and one of the largest of its kind in South Africa. Chryso South Africa is providing several admixtures to enhance the performance of the concrete, as well as a mould release agent and curing compound, to the Port Elizabeth-based concrete supplier, Scribante Concrete, and to the project’s principal contractor, Murray & Roberts Buildings. a.b.e. Construction Chemicals, also part of the Chryso South Africa Group, is supplying an extensive range of products, including epoxies and grouts, to M&R Buildings. The massive Baywest Mall project, on which work started in June 2013, is scheduled for completion in the first half of 2015. Situated in Port Elizabeth’s western suburbs, alongside the N2 motorway, the mall is the central component of the greater Bay West City project, for which the developers, Billion Group and Abacus Asset Management, have earmarked 300 hectares for development. As primary contractor for the project, Murray & Roberts Buildings is currently handling the construction of Phase 1 of the mixed development which will incorporate a light industrial sector, 7 000 residences and apartments, as well as retirement homes and a medical centre. Bay West City has been likened to Century City in Cape Town and it has been predicted

that this will be a catalyst project, “likely to change the way people think about the Eastern Cape”. Locally, it has caused an unprecedented sense of anticipation and excitement. The construction phase of the mall will ultimately create about 10 000 jobs, of which 3 000 will be through direct employment. After completion of the mall, a further 1 500 permanent jobs will be created by the retail outlets in the 9 hectares shopping centre with its 3,5kms of shop fronts. The tenant mix for the 264 shops on two levels will include anchor tenants, national chain stores and 12 cinemas. There will be parking for more than 3 200 cars. Patrick Flannigan, Eastern Cape

Area Manager for Chryso South Africa, says Chryso is supplying a number of products to Scribante Concrete , which has a dedicated ready mix concrete batch plant on site to supply about 57 000 cubic metres of concrete that will be needed for the construction of Phase 1: Chryso SA is supplying two products directly to the main contractors, Murray & Roberts Buildings and is also supplying ChrysoPlast Omega 136 admixture and Chryso Rescue Pack to Scribante Concrete for the concrete for the building of the new interchange that will provide access to Baywest Mall from the N2 highway.

Enquiry No: 62

Short Courses the answer

t takes up to fifteen years for an Engineer to be sufficiently experienced to serve in a managerial capacity. Developing appropriate development plans, mentoring and coaching and training to grow this talent from Graduate to effective Engineer is going to be critical in the future. An increasing number of engineers are participating in engineering and maintenance short courses that have been accredited or are in the process of being accredited for continuous professional development (CPD) points by the Engineering Council of South Africa (ECSA). When it comes to improving your employees’ skills it seems that there really is no substitute for a ‘live’ training course. By interacting with a roomful of your peers and having the opportunity to ask questions of subject matter experts and examine realworld applications of the information you’re covering really helps to cement new knowledge learned. The trick is to spend your training money wisely and Alusani Skills & Training Network offers over 175 courses in 19 different categories and is a Level 2 B-BBEE value adding supplier. It also offer Post Course Support for 12 months after the training course free of charge and are accredited with the Services Seta as well as offering a variety of CPD-validated training courses. Alusani Skills & Training Network was established in 2006 and has been offering CPD accredited training courses to the construction industry in the Eastern Cape area. Alusani has a huge portfolio of training courses that are critical to development in the Eastern Cape area, below is an upcoming public course coming to the Eastern Cape in 2014. • New Engineering Contract – 8, 9 & 10 September – East London • Effective Construction Contract Management & Administration – 29 & 30 September 2014 - Port Elizabeth Enquiry No: 63

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July / August 2014

COMPANY & PRODUCT NEWS

EC Industrial & Business News

East London – a powerhouse of ship repair skills

he Elgin Brown & Hamer (EBH) East London shipyard boasts a wealth of local skills and expertise in ship repair and general engineering. As a result of this repository of knowledge and experience, East London - the only river port in South Africa - has the capacity to cater to the growing offshore oil and gas industry. The East London port is therefore fast becoming a ship repair destination of choice along South Africa’s east coast. This is according to Marius Botha, General Manager of Elgin Brown & Hamer (EBH) South Africa’s East London branch. EBH South Africa, a ship repair company with almost 140 years’ experience, was acquired by the DCD Group in 2012. This resulted in the formation of the highly competitive DCD marine cluster, of which the East London branch is a part. “Since the acquisition of the East London Shipyard by DCD we have adopted a ‘group approach’: which means aligning ourselves

with the rest of the cluster, with a strong focus on resource-sharing and skills exchange between ourselves and our counterparts in Durban and Cape Town,” says Botha. “Sharing best practices has put us on the road to

becoming even more competitive and is creating a culture of continuous improvement.” EBH East London offers comprehensive ship repair services to a range of vessels, including platform supply vessels for the oil and gas industry, as well as dredgers, tugs, tankers and container ships up to 200 meters in length. Specialist services include hull preparation and painting, valve inspection and repairs, steelwork, pipe renewals, load testing of hoists and gangways, propulsion systems inspection and repairs and electrical systems inspection and repairs. “Our superintendents and artisans in marine, painting and mechanical services have decades of experience between them, and for many of them this includes international exposure. This level of expertise is invaluable in the shipping industry,” says Botha. “However, it is critical that these skills are passed on to more junior members of our team to ensure organizational continuity and

sustainability,” he continues. “That is why we have embraced a drive towards training and skills development.” The company’s focus on training takes the form of both informal skills exchange programmes with the other EBH shipyards, as well as in-house mentoring of apprentices under the supervision of EBH East London’s own qualified and trade-tested artisans. The company also regularly invites students from local Further Education and Training (FET) colleges, to spend time in the working environment. These training days focus on areas which they are studying, for example, the field of project management. EBH East London has not only built up a solid skills base over the years, but has accrued a significant mechanical and workshop capacity, offering not only ship repair services, but also general engineering and fabrication. Enquiry No: 64

Faster bolting systems for wind farms

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or wind farms to be viable, they need to be erected in exceptionally windy areas. Ironically, to install them, contractors need relative calm; requiring wind speeds to dip below 15 kilometres per hour to raise, align and bolt a set of flanged support sections to the windmill’s foundation ring which, once complete, will support the power generating turbines. The weight of the support sections, which can easily total between 80 and 120 tons, means that heavy-duty cranes, along with dedicated installation teams, need to be on standby until weather conditions allow for erection. Furthermore, to help ensure structural integrity in winds exceeding 60 kilometres per hour, each flange must have anything between 80 to 120 bolts torqued or tensioned in the correct sequence and to exact levels. This is time consuming since a single windmill can feature up to 1 000 bolts, and an entire wind farm of 15 or more turbines, in excess of 15 000. This makes wind farm erection exceptionally expensive and sometimes even risky as erection teams tend to rush to complete installations before wind speeds pick up. With wind power technology in its infancy in South Africa and with 28 wind and solar projects recently announced by the South African government, EPCM companies are placed under enormous pressure to find the best installation techniques and equipment available with the goal of reducing costs and enhancing safety. Keeping up with the latest installation techniques in Europe, Power Team, a Hytec Group company, has introduced the SPX Bolting System for windmills to the local market, enabling contractors to significantly increase windmill erection speed, reduce construction costs and ensure accurate torque and tension levels on every bolt. “Because of the small time frames allocated for windmill installations, speed is the main benefit of the SPX Bolting System,” says Ian Bennett, General Manager at Power Team SA. “The system includes a hydraulic TWHC (Torque Wrench High Cycle), the PE 45 continuous pressure pump, a compact pump, electric pump and wind tensioners.” Unlike standard two-stage hydraulic bolting systems that drop to low pressure for second and third-stage torqueing, the SPX Bolting System introduces infinite stage pump technology, which sees pressure drop in carefully controlled intervals. This means that, when it’s time for the second and third round of progressive torqueing, wrenches have exactly the correct pressure, which enables significantly faster bolting – up to 200% faster. “This technology is unique to the SPX Bolting System,” he says.

Warranty from Barloworld Equipment Fully inspected and serviced machine Machine condition up to strict Cat standards Only serviced with Genuine Cat Parts For more information contact our call centre on 0800 21 22 48 or visit www.barloworld-equipment.com

Enquiry No: 65

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July / August 2014

COMPANY & PRODUCT NEWS

EC Industrial & Business News

Going the extra mile to get the job done

espite living in the age of high technology and convenience, sometimes situations demand a more traditional approach to accessing essential information. This was the case recently when Royal HaskoningDHV was appointed to prepare the Alfred Nzo (Mbizana) Coastal Management Programme (CMP) in terms of the National Environmental Management: Integrated Coastal Management Act, Act No 24 of 2004 (ICM Act). The Alfred Nzo District Municipality, with only a single coastal local municipality, identified coastal zone management as one of three aspects crucial to creating a conducive environment for economic growth and better access to services. The Mbizana Local Municipality described its coastal environment as it’s “most prized natural resource.” A CMP is intended to provide the policy direction required with particular emphasis on establishing an agreement between coastal communities, the local and district municipalities as well as the relevant national departments. A CMP also provides a consistent link and

alignment with national and provincial CMPs and the national estuarine management protocol. “As a result of the relative inaccessibility of the Mbizana coastal zone by vehicle, the site visit to assess local conditions, to ground truth information and assess data, demanded that our team ‘think out the box’ and come up with an innovative solution. We elected to make use of the almost defunct Amadiba hiking and trekking trails.”

“Setting off before day break from Durban we drove to the Wild Coast Sun hotel where we hiked the initial 14km from the northern boundary, crossing two rivers via local ‘ferry’ and then via horse-back. With innovative and somewhat suspect tackle, we travelled the remaining 10km to the southern boundary. The team, including client representatives, spent the night at the Mtentu Lodge and rested our weary and somewhat bruised bodies. “The second day entailed more horse-riding, this time going past the rocky shore we had missed the day before, followed by a three hour trip by ‘wild coast taxi’ back to the Wild Coast Sun. After a final look at the beach we headed back to Durban.” Breetzke’s team will now report on the status quo of the various sectors that influence coastal management issues in an inventory analysis. The drafting of the CMP document follows and will be implementation focused, ensuring that the knowledge generated by the inventory analysis component will be incorporated into a decision-making framework (among others). Enquiry No: 66

First wood protection nets

he novel, patented net technology, Storanet, has received registration for commercialization in Germany. BASF can now provide the first non- liquid technology to prevent pest problems in harvested timber. Since it does not need to be applied with conventional spraying systems, it can significantly reduce the risk of exposure for operators, as well as the environment, making the net a significant improvement towards more

sustainable forest protection. Storanet is a high performance net coated with an insecticide, specifically designed for covering or wrapping timber piles. The fibers in the net are treated with an exclusive coating technology developed by BASF that controls the amount of insecticide available on the surface of the net. Due to this process, Storanet uses eight times less active ingredient than conventional treatments, still achieving the same level of control. Furthermore, BASF’s solution can be used in some conservation areas, where spraying is highly restricted. This technology also offers economic benefits. It is quicker to apply and when reused as recommended, can reduce treatment costs by up to 70% compared to liquid insecticides.

“With this pioneering approach, we are certainly changing the face of wood protection. The only products on the market to combat bark beetles are liquids and have to be sprayed. With Storanet , we will help our customers save precious application time and achieve consistent, quality performance,” said Thomas Zühlke, Forestry Manager Europe BASF Crop Protection. The nets can be used at any level of pest pressure, weather conditions and type of forest situation all season long. Furthermore, safe and easy handling allows application without special training. “The nets retain their efficacy for six months, can be reused up to five times and can be disposed of in an environmentally compatible way,” explained Zühlke. Enquiry No: 67

Telecommunication and data line protection

altek’s Class 1 BDG-24 lightning current arresters are designed to protect two-wire telecommunication, data and other lines, as well as the communication interface of measurement and control, electronic security and fire detection systems against direct and indirect lightning strikes. Combined with coarse and fine surge protection, the arresters are used at the boundary of LPZ 0A – LPZ 1 and higher. The arresters are installed directly before the protected equipment. The lightning current arrester and coarse surge protection

prevent longitudinal overvoltage (core– earth). A three-level combination of lightning current arrester and coarse and fine surge protection prevents lateral overvoltage (core – core). With a total 5 kA (10/35µs) impulse current and a nominal 10 kA (8/20µs) dis-

charge current BDG-24 has a 1 ns response time and mounts on a DIN rail. The arrester has a -40°C to +80°C operating temperature range and meets IP 20 protection requirements and conforms to the EN 61643-21 standard. Saltek is represented locally by Enquiry No: 68 Surgetek.

Vision sensor for manufacturing processes

fm electronic’s Dualis vision sensor can solve a variety of inspection and error-proofing applications throughout the manufacturing process providing the simplicity of a standard sensor and the high performance of a vision system. Dualis is a compact, highly-durable CMOS image sensor providing reliable performance in production control. Components are reliably detected and precisely evaluated with the sensor’s fast image capture and processing algorithm. The sensor’s Ethernet process interface allows quick adjustment to an application. Applications include contour matching, sortation, verification, part/no part, orientation, object character verification, recipe and measurement. Application parameters are quickly established using the sensor’s Setup Wizard. The Wizard guides the user in a few steps to configure an application. The software can be downloaded at no cost by visiting ifm’s website. ifm’s Dualis vision sensor offers a price-toperformance ratio that allows the sensor to be used throughout a plant for error-proofing applications. The sensor has a robust design and a compact metal housing that provide long life and reliability in industrial environEnquiry No: 69 ments.

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COMPANY & PRODUCT NEWS

Air piping system range A

tlas Copco Compressor Technique and its appointed distributors are the sole suppliers of AIRnet to the Southern African market. “Although similar products are available, the AIRnet range is specific to Atlas

Copco,” explains Wayne Jacobs, Business Line Manager of Atlas Copco Compressor Technique Service Division. “AIRnet is a compressed air piping system that delivers quality air exactly where you need it, from the compressor to the point

Speed, Power, Precision. WE HAVE WHAT IT TAKES.

of use,” continues Jacobs. Thanks to Atlas Copco’s innovative technology, the AIRnet system offers low friction and seamless connections. “This translates to reduced pressure drop and ultimately lowers the cost of ownership of your air system.” The extensive product range includes; AIRnet Classic and PFSeries. The high quality pipe material is made with Aluminium Alloy and the fittings with Polymer, allowing for temperatures from -20C to +80C at 16 bar gauge. “We recently introduced a new type of fitting that allows for higher pressures and different temperatures while at the same time making it more reliable,” reveals Jacobs. AIRnet is suitable for most compressed air applications needing diameters from 20mm-

July / August 2014

EC Industrial & Business News

100mm. For customer convenience AIRnet has been specially engineered to be compatible with all compressed air and nitrogen applications within the same operating parameters, irrespective of compressor brand; the system is suitable for all indoor applications. AIRnet is available throughout South Africa as well as in Namibia and installations are done by accredited installers and distributors. AIRnet’s smart design and low weight materials ensures a fast installation time. Both AIRnet pipes and fittings can be assembled in just a few simple steps by a single installer without the need for heavy machinery. The system is so user friendly that it can be installed by the end-user with very Enquiry No: 70 little training required.

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eriving its DNA from the legendary pedigree of Caterpillar’s extensive tracktype tractor range, the new Cat D5R enters the market as a versatile machine for construction and general industry, catering for diverse applications that include production dozing, fine grading, ripping, land clearing, back-filling and landfill operations. Cat D5R units sold into the southern African market are fitted with an enclosed, air-conditioned cab. Characterised by Caterpillar’s distinctive elevated-sprocket undercarriage design, the Cat D5R features a differential steering system, load-sensing hydraulics and an integrated power-train driven by a Cat C6.6 engine that generates a maximum net output of 120 kW and a torque rise up to 50%. A new aluminium bar-plate radiator effectively cools the engine in high ambient temperatures and provides superior corrosion and abrasion resistance. Depending on the undercarriage system and blade configuration selected, operating weights range from approximately 16 672 kg to 18 584 kg.

Electronic sensitive switches

egrand’s Arteor electronic switches, which are sensitive to a gentle ‘swipe’, have gained popularity in applications which require pristine hygiene standards, especially in commercial and healthcare installations. These switches, which don’t require the effort of manual push button control, have also

Clutches in the Cat D5R’s 3F/3R planetary power-shift transmission incorporate Caterpillar designed, oil cooled friction discs specially engineered to tolerate high stress in severe applications and to effectively dissipate heat for prolonged service life. An Electronic Clutch Pressure Control system permits on-the-go changes of direction and speed by modulating clutch engagement and protecting components from excessive torque loads. “The D5R’s differential steering system maintains power to both tracks when the machine turns, allowing operators to manoeuvre and retain large blade loads for added productivity,” explains Barloworld Equipment group product & application manager, Johann Venter. (Barloworld Equipment is the Cat Enquiry No: 71 dealer for southern Africa.) been developed for the convenience of paraplegics. Arteor sensitive electronic switches, with a 100/240 VA capacity, control light sources by simply passing a hand in front of the switch. Technology of the micro sensor has been designed that any movement further than 5 mm from the switch will not trigger turning on or off the light. These units have a LED indicator light as standard, to show the status of the current load – on or off. Legrand’s range of Arteor switches also includes mechanical, push buttons and automatic switches, as well as dimmer and double Enquiry No: 72 pole switches.

High precision hydraulic chuck

he CoroChuck 930 high precision hydraulic chuck from Sandvik Coromant has enjoyed considerable success since its launch in 2013. Now, demand from BIG PLUS users for a secure tooling performance in milling and drilling operations has led to the additional availability of the chuck for this patented spindle system. Ideal for meeting the demands for high runout precision, extensive tests have shown this new hydraulic chuck provides the best pull-out resistance available on the market. The secret behind its accuracy and pull-out security can be found in the optimized design of the brazed clamping membrane. This promotes ultra-secure clamping with two supports on each side (fulcrums). Ultimately, there is significantly less risk of tool pull out which has been previously witnessed frequently when using high helix tools. This unwanted effect is particularly troublesome in the aerospace industry when pocketing large aero-frame structures such as wing skins and ribs. If pull-out goes unnoticed, entire components might have to be scrapped if the cutter has been inadvertently cutting at a greater depth than intended.

Enquiry No: 73

July / August 2014

COMPANY & PRODUCT NEWS

EC Industrial & Business News

Feeding and cutting machine

elcro is such an ordinary part of our lives requiring a sturdy yet temporary attachment. Festo recently worked on a pneumatic application to automate feeding and cutting of Velcro lengths for a customer. The application involved the feeding of Velcro strips from a roll, adding of the non-stick strip on the reverse side and cutting the strips into preset lengths. Previously, an operator unrolled and cut the Velcro into strips by hand. This resulted in unreliable quality, uneven cuts and lengths. With the new automated solution from Festo, the system performs 15 times faster than the manual operation, with better quality

control, effectively paying for itself in less than six months. At the heart of the machine is the feeding mechanism. The customer required a repeatable rotary indexing motion from a pneumatic actuator. Festo’s DSR rotary actuator in combination with the FLSR Freewheel unit was the perfect solution. The Freewheel unit is attached to the drive shaft of the rotary actuator. When the actuator moves through its predefined angle of rotation, the Freewheel unit follows the movement reciprocally. When the actuator reverses its motion, the Freewheel drives shaft remains in its current position until the actuator drives it forward again, hereby creating an oscillating, rotary

Smart servo cables

abling technology is in a race to keep up with ever-changing technological advancements in the fields of electronics and electrics. As the popularity of controllable drives increases throughout all sectors of industry, so too has the requirement grown for digital interfaces that allow users far greater control of servos with full position and control information being relayed to the interface via data cables. Until now this called for a separate data cable and power cable which required special considerations in terms of available space etc. In addition two cables meant doubling up installation and protection required. To meet these requirements, advanced cable manufacturer, Helukabel, recently developed and

introduced a new hybrid cable that simplifies the operation and movement of drives by allowing both power and data to be transmitted via a single cable. The Topserv Hybrid, is a single cable solution that has been specially developed to power servo motors and transmit data to encoders.”We are expanding our standard servo cable range with the hybrid family of single cable solutions to provide users with the ability to save valuable space, reduce weight and streamline connection technology. “These cables are polyurethane (PUR)-jacketed which makes them ideal for dynamic drag chain applications and the addition of polyvinyl chloride (PVC) assist in applications

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index. The angle of rotation on the DSR can be set, and in this case that translates into what length of Velcro the machine should cut. A special requirement of the system was for easy set-up, cost effective running and low maintenance. Festo installed the standard round DSNU cylinder with the patented PPS selfadjusting automatic end-cushioning to actuate the cutting function. This means that the cylinder does not require any manual adjustment on installation; a quick and easy solution which saves time. It also automatically adjusts the cushioning during use, thus ensures less vibration of the machine during operation, extending Enquiry No: 74 the life of the system.

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requiring drag chains with limited movement,” says Doug Gunnewegh, managing director of Helukabel South Africa. He says that the digital pair is integrated in the servo cable for data transmission, which allows durability of the data shield and seamless power transmission. Durability was another serious consideration and the range was subjected to rigorous testing before being introduced into the world market recently. “We conducted in-house testing at our Windsbach production and watched for traditional cable issues, such as corkscrewing and breakage, while keeping an eye on quality and durability of the copper shield which protects the data pair from power core Enquiry No: 75 faults.

Reliable, safe, chemical handling identification

or many years now, Traceability Solutions has been providing reliable part marking solutions for all industries, backed up by reliable and friendly technical support, and now our range has extended even further to include state of the art Chemical Handling Identification. Traceability Solutions has secured the agency for S+P Samson Industrial Identification, who specialise in the manufacture of robust plastic labels and tags under the motto “Strong

solutions for rough environmental conditions”. Their range of labels, which meet the globally agreed United Nations GHS regulations, are ideal for chemical handling identification. These regulations require that safety symbols be printed in colour, and this range of labels are easily printed using colour laser printers and multi-colour thermal transfer printers. S+P Samson has optimised its portfolio for GHS regulations according

to the suitability of specific material for colour printing systems, and are extremely robust and UV resistant. They adhere perfectly to difficult surfaces and are also sea water and high temperature resistant. This is just one of the items in the wide range of industrial labels and tags available from S+P. Traceability Solutions offers products and services for any marking and identification application. The company stand for brand protection, and against counterfeiting of products. They offer solutions giving your products the mark that they deserve.

Oil and gas Component solutions www.sandvik.coromant.com/oilandgas 64 Jet Park Road, Jet Park | PO Box 25038, East Rand, 1462 Branches: Durban, Port Elizabeth, Cape Town, Vaal Triangle Direct Sales: 0860 101 008 Fax: 0860 101 006

Enquiry No: 76

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2014-05-29 14:45:17

July / August 2014

COMPANY & PRODUCT NEWS

Seen at The Forum event hosted by Nedbank are, from left, Joanne Solomon, Nedbank Corporate; Jackie and Paul Lippstreu, The For Childrens Trust

Also at The Forum event, from left, Chris Pouroullis, ACP Properties; Mike Palframan, Nedbank Corporate; Keith Buhr, Coega Development Corporation (Pty) Ltd

Also at The Forum event, from left, Graham Boyd, Boyd Valuations (Pty) Ltd; Frank Berkeley, Nedbank Corporate; Gerhard Olivier, Schol Property & Consulting Group (Pty) Ltd

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What lies behind ABB Low Voltage switchgear?

Complete compliance. What lies behind IBN - switchgear.indd 1

Eurodrive and Pneumax, visited the NMMU campus to introduce the fundamental elements of the learning opportunity and the competition guidelines. The aim of the PneuDrive Challenge, a competition which was set up in 2008, is to give the best mechanical, electronic and mechatronic engineering students a chance to use their talent to bring together engineering theory, the latest technology in drive engineering, pneumatics and business reality. More than 40 third year NMMU students who are specialising in Mechatronics were taken through the

structure of a suggested project plan and introduced to the latest drive and pneumatic technology that could be used in the warehousing and logistics industries. Industry mentors have been made available and students have until 13th October 2014 to submit Enquiry No: 77 their design ideas.

A ‘Package Deal’ for businesses

he need to procure and stockpile pre-made boxes and filling materials could be a thing of the past with a new packaging product, CMC’s CartonWrap, an innovative new system which produces various sized boxes, in line and on demand. Manufactured by CMC, CartonWrap represents a new concept in automated packaging, aimed at e-commerce businesses and other companies which have a wide variety of packaging needs. This is according to Victor Queiroz, Executive Manager at Pitney Bowes South Africa. “This product, which is distributed, serviced and supported by Pitney Bowes South Africa, enables boxes of varying sizes to be produced from an inexpensive corrugated cardboard reel in real time, at high production speeds in a stand-alone or production line configured environment,” says Queiroz. He adds that the Cartonwrap can be configured to meet customers’ workflow needs such as adding instruction

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Young engineers re-thinking greener logistics

he South African logistics industry is becoming increasingly aware of the need for greener supply chains, and who and what technology can be accessed to not only decrease demands on the environment, but also possibly influence the total cost of ownership. The PneuDrive Challenge 2014 Engineering Design Competition, sponsored by SEW-EURODRIVE and Pneumax, has welcomed the involvement of engineering students from the Nelson Mandela Metropolitan University (NMMU) to this year’s national competition. This year NMMU students will join young engineers from five other South African universities who have been challenged to use their academic ability and youthful creativity to design solutions that can contribute to “Greener Warehouse Logistics Systems”. In late April 2014, the PneuDrive Challenge team, made up of business and engineering experts from Sew-

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Issue 62 - July / August 2014

EC Industrial & Business News

manuals, packing lists, invoices, shipping tariff calculations, labels a n d many other functions. These are all automated on a single line in one single step, with total integrity, product traceability and a 100% audit trail. “The CartonWrap provides a flexible, on-site solution for varied packing needs with the benefit of a significant reduction in packaging materials and shipping volume. “ “We believe that users of CartonWrap can expect many benefits, including effectively lowering operational and shipping costs, improving customer satisfaction and significant environmental benefits in their packaging processes,” comments Michael Springer, MD of Pitney Bowes South Africa. The boxes are formed around the product to be packed, based on product dimensions which are fed to

Quick Connect Nozzles

praying Systems Co. has recently expanded its range of quick connect nozzle systems to include double clamp assemblies for higher pressures, deflected flat spray tips and miniature quick connect nozzles. With quick-connect nozzles and quick-change nozzles, the body stays on the header – only the spray tips are replaced, lowering costs by changing out just the tips, and cutting maintenance time. Most quick-connect nozzles allow tips to be removed and installed by hand and offer automatic alignment. With dozens of different quick-connect styles, you’ll find the

exact performance you need for almost any operation including cooling, cleaning, coating and metal finishing. QuickJet spray nozzles require a quick 1/4-turn of the wrist to remove spray tips. No tools are required. Choose from flat spray, solid stream, full cone and hollow cone versions with angles from 0° to 170°. Material options include brass, stainless steel and ProMax, an engineering grade of polypropylene. Quick-connect nozzle systems allow

the carton former by means of a scanner at the start of the process. An infinite range of box sizes can be produced, eliminating the need for stockpiling pre-made boxes. There is no wasted packaging material, no requirement for fillers, reduced storage footprint and optimised shipping costs. Not only is CartonWrap environmentally-friendly, because it minimises packing waste, but it is also userfriendly. An intuitive operator interface facilitates ease of use and quick machine set-up. Enquiry No: 78

you to mix and match bodies and tips to get the exact performance you need. Choose ProMax or polypropylene bodies that easily snap-on the pipe header using a clamp or screw into the pipe header. Both body styles can be installed by hand, without tools. Then, choose your tip style and install, align and position it easily by hand. A wide range of spray patterns, spray angles, connections and capacities are available Ideal for: • Coating, lubricating, chemical application • Cooling, humidifying, moistening • Cleaning, washdown, rinsing • Metal finishing Enquiry No: 79 • Parts washing

Designers of low voltage installations require automation and distribution switchgear that passes the rigors of extensive testing, required to fully comply with all the requirements of the IEC 61439-1, 2 and IEC 61641(arc-fault containment) standards. ABB switchgear, from proprietary high-end through to modular panel builder-suited solutions, meets and surpasses the performance requirements. ABB low voltage switchgear provides complete peace-of-mind. For additional information; www.abb.co.za/lowvoltage ABB South Africa (Pty) Ltd Tel. +27 10 202 5000 E-mail: LP@za.abb.com

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