Ec industrial & business news issue 66 by The Media & Events Company

EASTERN CAPE INDUSTRIAL & BUSINESS NEWS

YOUR LINK TO INDUSTRY THROUGHOUT THE EASTERN CAPE

issn NO: 1996-9708

MARCH / APRIL 2015 issue R17,10 (VAT incl.) no. 66

Inside New to renewable energy sector - page 3

Instrumentation, Measurement & Control - page 7 Food & Beverage page 9

Pumps, Valves, Pipes & Fittings - page 12 Hydraulics & Pneumatics - page 16

Agriculture - page 17

Company & Product News - page 18

Renewable energy sector boost for EC

he Department of Economic Development, Environmental Affairs and Tourism MEC Sakhumzi Somyo (pictured) announced recently that the East London Industrial Development Zone (IDZ) is to develop its own wind farm which will produce in excess of three million kilowatt-hours per annum. In presenting his policy, MEC Somyo said that the entity, which was working with a local wind turbine manufacturer, would save R98 million in electricity costs over 20 years and strengthen energy security for its industries. Somyo also reiterated the province’s continuing interest in shale gas, saying that the province’s research partner, the Nelson Mandela Metropolitan University, was making history with a first-ever forensic baseline of ground-water

chemistry and three-dimensional image of the Karoo’s deep subsurface. These developments follow a litany of renewable energy milestones which has seen the province develop a sizeable renewable energy footprint with its independent power producers (IPP) securing licenses for 12 wind farms and one solar farm. He pointed out that while renewable energy production had the effect of securing electricity supply for the province, the IPPs’ enterprise and social development programmes amounted to R1.6 billion which would benefit local communities over the 20 year life of the projects. It would also create over 10,400 jobs (for one year) over their lifetime, with 1,220 jobs at peak construction. Local content, which was to be procured from within the province, was projected at R7.5 billion and

would stimulate the development of localised industries and the green economy. Already eight manufacturers were established in the province; the three manufacturers are in the East London and Coega Industrial Development zones, and represented a combined investment of over R1 billion. Energy security has also been given a further boost at the Coega Industrial Development Zone where the R3,5 billion Dedisa Peaking Power Plant confirmed that it expected to go online later this year. During construction, this project created more than 1,000 jobs. This plant would generate 342 mega-watts of electricity through its open-cycle gas turbines. Somyo pointed to the need for skills development in this area, and said that in one such initia-

tive, the University of Fort Hare with the Department of Science and Technology was implementing a R9 million biogas project which generates electricity from the waste of the university’s piggery. In time, this electricity will power a university agripark where a community cooperative dries vegetables. The university is working on a project with the South African National Energy Development Institute where it is to install 110 household biogas digesters. The project will also allow for the training and contracting of local installers. Somyo added that other sectors which the province believed were the most promising for boosting the economy and created jobs were the agro sector and “ocean economy”.

of Marketing and Communications. “The existing expertise, skilled labour and logistics services from the Eastern Cape’s automotive and manufacturing industries are important strategic advantages that can support the development of aeronautical and aerospace manufacturing in the region,” added Dr Vilakazi. “Included in our plans is the construction of the cargo/industrial air-

port that can serve aeronautical and aerospace industrial manufacturing. Subsequently this will also offer tenants and investors in the Coega IDZ with an immediate facility for air transport, which have been well received by the industry with Letters of Intent and Expression of interests already indicated,” concluded Dr Vilakazi.

Enquiry no: 1

EIA for Aeronautical Manufacturing

HE Coega Development Corporation (CDC) recently announced that it will issue a notice for an Environmental Impact Assessment (EIA) study to assess the feasibility of establishing a cargo airport and an aeronautical/ aerospace industrial cluster in the Coega Industrial Development Zone (IDZ). “We are happy that the project is beginning to take shape. Feasibility work has been done by industry experts which has yielded great potential for the project. The establishment of an advanced manufacturing cluster for aeronautical and aerospace industries has always been on our vision map,” said Mogamad Sadick Davids, CDC metallurgy business development manager. Possible aeronautical and aerospace industrial manufacturing activity that can take place in the Coega IDZ include manufacturing

of helicopters, aerospace engines, auxiliary equipment and parts, and propulsion units while the industry can also possibly contribute to aerospace product prototypes, aircraft conversion and aircraft overhaul and rebuilding. The planned cluster will be located in Zone 14 of the Coega IDZ, which currently stretches across 2 086 hectares of land. “Through the environmental impact assessment, we are a few steps closer to developing a possible new industry for Nelson Mandela Bay, ensuring further broadening of the economic base and growth through diversified industrial sectors and development for the region,” said Davids. “Industrial clustering for mobility industries is an accepted form of economic organisation across the world,” said Dr Ayanda Vilakazi, CDC head

Enquiry no: 2

March /April 2015

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EC Industrial & Business News

Knowledge is power

ime flies, seeming to gather speed as the years past. This point was driven home at the Alexander Forbes Ready Set Retire conference in Port Elizabeth when MC Peter Ndoro showed the crowd a picture of himself as a sixyear-old, and confessed that he was turning 50 the following day. “I still remember that photograph being taken,” he said. Individuals at the conference, held at the Boardwalk Convention Centre in March and aimed at empowering those nearing retirement with the correct skills, were encouraged to retire later and save more. Time, according to panellist and former Personal Finance editor Bruce Cameron, himself now retired, is what is “required to accumulate wealth so that you can live off it”. Cameron outlined post retirement risks as having insufficient savings, inflation, making incorrect annuity choices, consumption and medical cost inflation.

Seen at the event from left, Elizabeth Ferreira and Eileen Gardner (Goodyear) with Alexander Forbes' Belinda Sullivan “You might think you do not have money to save but you have to sit down and say, I’m not going to buy a new car every two years. Choose a cheaper car and live a better life in retirement,” said Alexander Forbes senior

Manufacturer,

wealth manager Andrew Auld. If you start saving aged 20, your replacement rate of a person saving 15% of income generating a 3% real return, retiring at age 65, is 58.58%. If you start at 60 and retire at 70, your replacement rate is reduced to just 12.54%. John Anderson, Alexander Forbes MD of research and product development, touched on understanding the realities of your retirement decisions and encouraged attendees to examine how they wanted to spend their retirement. “International studies show that you need between 70-90 percent of your salary before retirement, however the most recent South African research suggests figures closer to 100%.” Adult Development coach Cathy Yuill said the fourth chapter of one’s life, from 50 to 90 years, is filled with possibility and potential for change and growth, and new learning.

Enquiry no: 3

government partnership creates 500 internships

EC for the Department of Economic Development, Environmental Affairs and Tourism MEC Sakhumzi Somyo announced that in a landmark agreement, the department had entered into an agreement with Mercedes-Benz South Africa (MBSA) to create 500 internships opportunities after which 360 trained artisans will be permanently placed. The MBSA Learning Academy, which has been established in partnership with the East London IDZ and Buffalo City Technical and Vocational Education and Training (TVET) College, will help to address the skills shortage in East London in the private and public sector. The East London automotive manufacturer and one of the largest employers in the city said it intends to draw artisans and interns from academy into sustainable employment at its plant. MBSA will also source state of the art technology and equipment for the academy while technical experts will share skills with the learners. Somyo said that he anticipates that the investment will attract other companies who have been sceptical of investing in East London due to the skills shortage thereby unlocking potential for new job opportunities. He pointed out that the competitiveness of the automotive sector in the Eastern Cape was constrained by insufficient sector specific skills, low local content production levels in the Original Equipment Manufacturers (OEMs) and the absence of a metal surface treatment plant. The Automotive Industry Development Centre in the Eastern Cape and the Jobs Fund were co-funding the initiative. The initiative comprises three interrelated projects in the automotive industry’s value chain: the engineering and supplier skills development programme, the manufacturing business incubators in Mdantsane and Nelson Mandela Bay; and the Metal Surface Treatment (MST) facility in East London. The MST facility will create 446 permanent jobs Enquiry no: 4 and place 68 graduates.

EASTERN CAPE INDUSTRIAL & BUSINESS YOUR LINK TO INDUSTRY THROUGHOUT THE EASTERN CAPE

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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. PUBLISHED BY: Hentiq 1910 (Pty) Ltd t/a THE MEDIA & EVENTS CO Reg No. 1999/019445/07 COPYRIGHT: All rights reserved

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New to renewable energy sector

OLLOWING significant growth in its renewable energy business, AfriCoast Engineers SA has developed a sister company to expand its vision. The engineering firm announced that new company, AfriCoast Energy, will now be responsible for all future renewable energy projects – particularly wind and solar – while it will also play a key role in guiding AfriCoast Engineers’ current basket of renewable energy projects. John McGillivray, former project director at AfriCoast Engineers SA, has been appointed chief operating officer at AfriCoast Energy. “AfriCoast Engineers SA’s growing footprint in the renewable energy sector over the past ten years led to the establishment of AfriCoast Energy to follow opportunities within the renewable energy and sustainability sectors.” “We are pursuing large, medium and small scale renewable energy projects with a collective capacity of over 2000 MW, working closely

AfriCoast Engineers SA directors (left) Donald McGillivray and Venance da Silva (right) congratulate John McGillivray (centre), chief operating officer of AfriCoast Energy

with energy developers, investors, the state and private landowners,” McGillivray said.

Over the past decade, AfriCoast Engineers SA has played a catalytic role in bringing renewable energy projects online in the country. To date it has delivered projects collectively worth over R4-billion for its local and international client base. In the first stage of the Department of Energy’s Renewable Energy Independent Power Producers Procurement Programme (REIPPP), the firm initiated three out of four of the successful Eastern Cape projects between 2011 and 2014, and a successful round three project. Now, through AfriCoast Energy, it will continue to provide the expertise that has been at the core of renewable energy projects such as the MetroWind Van Stadens, Gibson Bay and

Kouga windfarms, and the Dobbin, Brakpoort, Hopewell and Coega solar projects. McGillivray, an engineering project management and consulting veteran of projects in England, South Africa, Australia and the United States spanning over two decades, said AfriCoast Energy has laid out an ambitious plan to continue pioneering new models in renewable energy development for government, communities and private sector entities. “We were privileged to work with Amatola Green Power in pioneering embedded generation and energy trading in South Africa through an innovative trading model and a ground-breaking agreement with the Nelson Mandela Bay Municipality in the Eastern Cape. We would like to extend this concept to the remaining provinces of the country,” he said. Enquiry no: 5

Major boost for NMMU InnoVenton

ASF South Africa’s continued relationship with the Nelson Mandela Metropolitan University (NMMU) in Port Elizabeth has seen the German chemical company further sponsoring a computer laboratory for the NMMU InnoVenton Institute for Chemical Technology. The relationship between InnoVenton and BASF began in 2007 with staff from the company’s laboratories attending various specialist training courses at the Institute. In 2010 BASF, along with partner companies in the chemical industry, namely PetroSA, Umicore Catalyst SA, and Heraeus South Africa, played an integral role in the development of an industry-specific programme which will ultimately

At the NNMU Trust/InnoVenton cheque handover ceremony were (left to right): Linda Brown, Site & Media Relations Specialist, BASF Holdings South Africa; Renita Affat, acting CEO NMMU Trust; Paul Allday, Site Director, BASF South Africa, Mobile Emissions Catalysts; Dr Shawn Gouws, InnoVenton’s CPT Programme Co-ordinator; Charles Johnson, Human Resources Specialist, BASF Holdings South Africa

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see the chemical process industry’s skills being further uplifted. A skills gap in the chemical-related qualifications on offer was identified so, together with the NMMU’s InnoVenton team, this group of industry leaders developed a 3-year National Diploma in Chemical Process Technology (CPT) which is now on offer at the NMMU. This diploma programme sees skilled process operators and controller technicians being equipped to not only control a process plant but also to support chemical and process engineers in various design and problem solving projects. The development stage of this qualification took three years to plan and gain all the necessary

approvals through the higher education qualification structures. Since the establishment of the CPT in 2013, BASF has sponsored a number of bursaries for students studying towards the diploma. The industry support extends further to on-site visits for the students in order for them to gain a hands-on understanding of the practical application of their studies. BASF’s donation towards the establishment of a computer laboratory for InnoVenton’s CPT programme will enable the students to complete modules on quality assurance statistics, applied mathematics and process simulation. Enquiry no: 6

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EC Industrial & Business News

Six essential tips for sound budgeting

business without a working budget is like a car without a fuel gauge – it will drive for a while, but will run out of fuel when the driver least expects it. In light of the recently announced 2015 Budget Speech, Gerrie van Biljon (pictured), executive director at Business Partners Limited, provides small and medium enterprises with six essential tips for sound business budgeting.

• Be realistic: The basis of every budget is an estimate of the income of the business. The more accurate the revenue estimate, the more sturdy and useful the budget is for the business owner. Van Biljon says however that the income estimate is often the portion of the budget that business owners get wrong. “As most entrepreneurs are optimistic by nature, they tend to overestimate projected sales. A budget with overstated income can be just as bad as having no budget at all, as it gives the business owner a false sense of security that budgeted expenses will be covered.” He recommends that business owners have two budgets – one for when things go well, and another for when the things turn bad, which should include a ‘break-even’ scenario and reflect the minimum sales required to meet overheads and keep the business going. • Keep it simple: Business owners don’t need a fancy app or expert set of skills to draw up a budget. Van Biljon says that budgeting is a basic exercise that every business owner can do on a simple spreadsheet with three columns – budget, actual and variance. “If you know your way around your accounting software and it allows you to draw up a budget, use it. But a simple spreadsheet is more than enough for managing your budget.” • Do it yourself: Accountants are useful for helping business owners with tax and financial statements, but business owners who leave budgeting to their accountants are probably over-reliant on them, says van Biljon. • Do it regularly: While large corporations go

through an annual budgeting process, it is probably better for SMEs to rethink their budget more regularly, as their resources are less likely to cover sudden external or internal upheavals. Van Biljon says that a budget drawn up for the next quarter is invariably more accurate than one drawn up for the next twelve months. “Whatever the frequency of the budget-planning process, it is important that any business compares its actual sales and expenses against the budgeted amounts at least once a month. If not, sales dips and rising expenses will only be noticed once it is too late.” • Budget for your extra cash: Budgeting is not only to prevent death by cash-flow crunch, but also to help entrepreneurs plan for what to do with extra capital. “Sensible budgets include plans to invest extra cash into accessible short-term money market accounts, for example, or into long-term investments, such as buying the building from which the business operates if the entrepreneur is sure that income and profitability can be sustained,” says van Biljon. • Be ready with Plan B: Over and above break-even budget mentioned before, sensible business owners should have a plan for when their budget, even their break-even budget, suffers a major knock, such as if a major client goes bust, a fire or break-in disrupts production, a key staff member quits, or an aggressive competitor suddenly emerges. “Entrepreneurs have the temperament to live with such risks. The best entrepreneurs plan for such possibilities, and always keep their budgets close at hand,” Enquiry no: 7 concludes van Biljon.

Logistics Park to grow business hub

HE purpose-built Nelson Mandela Bay Logistics Park (NMBLP) in Uitenhage managed by the Coega Development Corporation (CDC) is ready to accommodate more first and second tier suppliers in automotive manufacturing. Recent announcements by Volkswagen South Africa (VWSA) to offer a new car model have sparked interest in companies wanting to locate at the NMBLP. “Coega is working closely with VWSA and other Multi Original Equipment Manufacturers (OEMs) in attracting first and second tier suppliers to locate at the logistics park in anticipation for the new car model,” said Gustav Meyer, CDC senior manager: international markets (transport industries). “Planned expansions of current tenants such as Rehau and

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Q-Plas, related to future vehicle productions, are on the horizon and negotiations have started with several other companies interested to lease premises in the park in 2016,” said Mpumzi Flepu the NMB Logistics Park facilities manager. The park, which currently spans over 183 hectares, features purpose-built infrastructure and shared services which includes security, ICT and logistics to minimise costs for new investors and existing tenants. Current tenants in the NMBLP include Benteler Automotive (Germany), Faurecia Interior Systems (France), QPlas (SA), Grupo Antolin (Spain), Inergy Automotive Systems (France), Rehau (Germany), MSC, ITPASA and Hella SA (Pty) Ltd (Germany). Enquiry no: 8

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Citizens and Business: We can only start

where we are

e mark out time at the beginning of each year in speeches: First come the State of the Nation and State of the Province addresses, as barometers of the current status quo, and indicators of the direction in which we’ll move as a country and as a region. Next, South Africans wait in anticipation (some would say trepidation) for the national Budget and the provincial budget speeches. Now that we’ve reached a point where the country’s intentions for 2015 have been laid out on the table, it is up to business and civil society to take up the mantle and ensure that the actions and objectives of all stakeholders align. It is frustrating to many business owners when the immediate and genuine concerns of the citizens of this country are not addressed in the direct manner we believe is warranted by the country’s current challenges, especially in light of South Africa’s critical energy challenges. This year’s State of the Nation address by President Jacob Zuma should have held more signs of a fundamental shift in support policies for business and economic growth and development. And it was with disappointment and concern that we heard that, between the Provincial Department of Transport and SANRAL, no funding had been allocated to the upgrade of the Addo Road, which is critical to the citrus and tourism industries in our region, despite commitments by the President and his ministerial delegation in 2014. Business and citizens alike expressed concern at the President’s indication of the building of further Integrated Public Transport Systems in other cities, while Nelson Mandela Bay languishes with a non-functioning IPTS. There was further consternation at the fact that even with R1 billion made available to the province for water infrastructure, the critical Nooitgedacht Low Level Scheme, and the Fish Water Flats / Coega return effluent pipeline have not been funded. This, despite the critical nature of these two projects in ensuring that the region’s water infrastructure is in a state of readiness for future investments and mega projects. Happily, fiscal discipline was identified across the board as a necessary means of ensuring that South Africa delivers on its promise of sustainability into the future. In his Provincial Budget, the MEC advocated prudent efforts by the province to make whatever savings it can to guard against unexpected expenses and unwarranted expenditure. We welcomed, also, a shift of focus towards the implementation of the national ‘Back to Basics’ campaign in municipalities across the Eastern Cape, as it aligns with the view of the Civil Society Coalition in its efforts to form partnerships at a local level in Nelson Mandela Bay. The members of the Coalition are standing by to ensure that such partnerships are primed for the inputs of an active citizenry, and look forward to the promotion of dedicated and committed two-way partnerships that deliver on key focus areas and put the needs of the citizens of Nelson Mandela Bay first. We firmly believe that all stakeholders, including business and the representatives of civil society, should together pursue good governance, transparency and accountability. Through Operation Phakisa, the ocean economy holds immense opportunity for Nelson Mandela Bay. As the only city in the country with two ports, we have the opportunity to unlock the maximum potential of our coastline. Business would like to hear more from government about this, and it is imperative that they both consult and partner with the private sector and civil society to avoid the discontent brought about by poorly-handled proposals such as the Algoa Bay fish farm. As the voice of organised business, we will continue to advocate for partnerships that grow trust and accountability between all partners in our region and province. The longest journeys begin with a single step, and we can only start where we are.

March / April 2015

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EC Industrial & Business News

Facilitating EC business opportunities I

deally situated in East London, Second Office has created a unique, value-added solution for entrepreneurs and established businesses interested in tapping into the vast economic potential in the Eastern Cape, by allowing them to establish a risk-free presence in the area. “Many entrepreneurs are constrained from taking advantage of the economic opportunities available in the area by the cost and hassle of setting up and running a professional office,” comments Sibongile Booi (pictured), founder and MD of Second Office. “Established businesses, whether local, national or international, face a similar challenge when visiting the area to explore business opportunities, requiring professional offices, boardrooms and administrative services to support their efforts.”

Second Office was established in East London in 2011, offering entrepreneurs and out-oftown businesses professionally staffed, equipped and furnished offices, boardrooms, meeting and training space in Donald Road, Vincent, East London. These prestigious offices feature modern communication linkages, including highspeed Internet, and offers extensive administrative support, such as handling communication and providing comprehensive business services. This is available at competitive prices and highly flexible hourly, daily, weekly, monthly or longer-term rentals that ensure entrepreneurs and business people from all over the country can access the space and services they need to participate in the growth of the Eastern Cape.

“Quite simply, ‘You run your business, we run your office’,” says Booi. “Second Office offers a real solution for the realities of the modern business world, in which speed of response to opportunities and cost containment are crucial for success. This has given rise to rapid growth in virtual offices, which provide professional office space and support services on demand, allowing entrepreneurs and businesses to respond rapidly and cost-effectively to business opportunities without the hassle and costs involved in first finding, acquiring, furnishing and staffing offices from which to operate. With Second Office, entrepreneurs and businesses have on-demand, flexible and affordable access to professional office space in a secure A-grade building, while also enjoying the essential administrative support that creates a seamless and hasslefree business environment conducive Enquiry no: 9 to success. ”

The Nelson Mandela Bay Business Chamber recently celebrated the launch of its fourth annual list of Top 40 Under 40 achievers at The Plantation in Nelson Mandela Bay. Achievers are nominated each year by members of the Business Chamber and the general public, and judged by an independent panel of judges. The Business Chamber runs exclusive networking and development events on The Top 40 Network in an effort to build the connections of young business leaders in Nelson Mandela Bay.

Photo credit: David Dettmann Photography

High security groove milling

Pre-planning essential under new EIA regulations

RK Consulting, a leading provider of consultancy services to the global mining, metals and natural resource sectors, hosted a workshop on 19 February 2015 in Port Elizabeth during which the new NEMA EIA Regulations, and its implementation were discussed and clarified. The National Environmental Management Act (NEMA): Environmental Impact Assessment (EIA) Regulations, which came into effect on 8 December 2014, form part of a holistic attempt by government to consolidate regulations pertaining to the EIA authorisation process and support the development of an ‘One Environmental System’ for South Africa. SRK’s Rob Gardiner (pictured), Principal Environmental Scientist and a Partner in the firm, hosted the morning session together with guest speaker, Janice Tooley, Associate Partner at Shepstone & Wylie Attorneys.

Said Rob Gardiner: “The 2014 EIA regulations provide an opportunity to engage with stakeholders before the regulated process takes place, and we believe that this process should be used to identify and address potential conflict areas before the regulated EIA process commences.” With the arrival of the new 2014 EIA regulations, the importance of social licence to operate, stakeholder relationships and pre-planning has come full circle, with the permitting process currently being the only part of the new authorisation system to be regulated. “We think the amount of work required in an EIA remains essentially unchanged. What will be different is the design of the project will have to be more advanced than is usually the case at the time of commencing with the regulated process.

Call for Steel Awards entries

he Southern African Institute of Steel Construction (SAISC) has called for entries for the 2015 Steel Awards and photo competition. SAISC communications manager Renee Pretorius says that after the high standard of the 2014 Awards there has been extraordinary expectation throughout the steel construction industry in relation to this year’s Awards. Although the judges decide on the categories and winners based on the actual entries received, the following awards and categories will definitely happen: Overall Winner, Tubular Category, Light Steel Framing Category, Factory and Warehouse Category and a new category for carbon steel based cladding related issues. There are several factors that are considered when judging. These include: the importance of steel as a structural component of the project, benefits achieved by using steel construction, aesthetic appeal, environmental/ sustainability consideration, innovation in design, fabrication or construction, technical prowess required for realising the project, engineering expertise, exceptional quality of workmanship, tubular content, cladding: workmanship, innovation, special solutions, size, speed, architectural finish etc. and more. “In short”, says Pretorius, “the primary criterion for Steel Awards is: ‘Does the project illustrate what can be achieved with steel? The best photograph of any entry also wins an award. Enquiry no: 11

Our advice is to obtain input from the Environmental Impact Practitioner (EAP) before this so that environmental constraints and the views of key stakeholders can be addressed in the design at the outset of the formal process.” “There is a real risk that a change to the project description, once the formal authorisation has started, will result in deadlines being missed and the EIA then having to start again.” SRK’s view is that, the quantum of work required to undertake an EIA is essentially unchanged, however proponents should not be lulled into the false sense of security that all this work can be completed in the 300 day authorisation period.

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Enquiry no: 10

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Secure supply of industrial gas

NDUSTRIAL gas continues to play a pivotal role in the growth of Eastern Cape industry, evidenced by Air Products South Africa’s supply to the local market for the past six months of uninterrupted supply of industrial gases. The industrial gas company was commenting on its contribution to Eastern Cape industry following the launch of its R300 million air separation unit (ASU) in the Coega Industrial Development Zone (IDZ) in November last year. As the first to market in the Eastern Cape, Air Products is able to deliver security of supply of liquid oxygen and nitrogen, meeting the needs of local industry and offering improved levels of customer service, according to Pierre Fourie, Sales Manager: Eastern

March /April 2015

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Cape for Air Products. “Our air separation unit supplies liquid oxygen and liquid nitrogen in bulk by road tankers across the Eastern Cape. We also supply the full range of industrial and specialty gases. Depending on volume requirements and specific applications, gases are supplied in cylinders, mini-tanks, maxi-tanks and CryoEase,“ he says. “As gas is a vital part of virtually every industrial process, the importance of security of supply cannot be overstated. We are able to match current market demand and have capacity to scale up production in line with growing demand in the region,” he says. The company’s identified markets for growth, including automotive and component manufacturing and fabrication, food and beverage, agroprocessing and their related value chains, were well aligned with the

sectors prioritised for growth in the Eastern Cape’s provincial industrial development strategy. “Liquid oxygen and nitrogen play a key role in the metals processing sector for cutting and laser applications. Metals processing supports diverse industries, including the manufacture of renewable energy components – another key sector where the Eastern Cape is driving industrial growth,” says Fourie. “In the field of agro-processing, identified as a key growth area in the Coega IDZ, oxygen has many uses, such as in fish and prawn farming (aquaculture). Oxygen aerates and improves water quality,” Fourie explains. Air Products distributes liquid nitrogen and liquid oxygen by its newlyupgraded fleet of road tankers across the Eastern Cape, and provides onsite back-up storage for critical cusEnquiry no: 12 tomers.

EC Industrial & Business News

Holbrook’s Voice

n a recent media article the lack of funds in the East London Industrial Development Zone (ELIDZ) was highlighted. The Eastern Cape Development Corporation (ECDC) has also seen its fair share of negative media coverage regarding the Mandela Funeral scam, and resignation of the CEO, Sithembele Mase. It would also seem that after an 8 year hiatus, the Buffalo City Development Agency (BCDA) is finally being revitalised. After all the negative press coverage on locally based developmental agencies I find myself asking the question: Do developmental agencies work in the Eastern Cape? Let me clarify. Firstly, the criteria in which we measure these agencies, or yard stick as it were, is by the fulfilment of their mandate, which is issued by the South African Government, be it National, Regional or Local. Unfortunately, party interference, corruption, incompetence and cadre deployment interfere with developmental progress regardless of the institutions Vision, Mission and Values. While loan or grant funding disbursement forms part of some of the agencies key performance indicators (KPI’s) it is, after all taxpayer’s money being distributed and the future success of the agency lies within the reclamation of the disbursed funds from the revenue source. Secondly that it is our firm belief that these development agencies need to have formal business representation at board level as it is within the interest of business for these entities to succeed. Thirdly that it needs to have the full unfettered political support of the local, provincial or national government it reports to represent. Falling short of this support, it will not be able to enforce its given mandate when various obstacles,

The Role of Development Agencies and challenges arise from other government departments. The current key focus of several development agencies, along with economic development is that of job creation – whether it be through agrarian reform via the Eastern Cape Rural Development Agency (ECRDA) or through infrastructure and the renewable energy build programme by the Industrial Development Corporation (IDC). A concern however, is that of long term sustainability, and will those jobs still be there after the funding period. Time will tell. The IDC was Integral in implementation of infrastructure projects in and around South Africa, in particular the renewable energy projects in the Eastern Cape. More specifically, 1jobs created by the IDC from 2010 to 2014 is 7257. They have also distributed R3.798 billion. Well done. Similarly, 2The ELIDZ since the 2005/6 financial year has had an average of 5 new investors each year with an average investment value of R516 million per annum since the 2007/8 financial year. A mean feat by any standard. In conclusion, do developmental agencies work in the Eastern Cape? Most times YES. The unfortunate truth is that some agencies have failed their mandate. However, as mentioned in the previous two paragraphs some perform quite favourably. It is hoped that more would follow suit. Key to this in the long term is appointing the best and qualified personnel to manage these tax funded entities. It is after all, taxes that keep the entities afloat. As an aside, I am pleased to announce that the Border-Kei Chamber of Business has formed part of the strategic planning sessions to re-launch the BCDA. (Endnotes) 1 IDC Annual Report 2014 2 ELIDZ Presentation

Pneumatic factory automation in 2015

he premise of pneumatics cannot change. It is like a ball – if you change its shape, it is no longer a ball. While the wheel isn’t being reinvented, certain trends are geared towards shaping the industry in 2015. Here are four major ones, according to Festo South Africa’s Business Development Manager, Russell Schwulst. • Innovative air cushioning Gone are the days when a technician was required to manually set an actuator’s cushioning with a screwdriver. Depending on how many actuators you are installing, it can be a time-consuming and unproductive process. Improperly adjusted cushioning can cause substantial wear and damage to your machine. Pneumatic drives are now utilising self-adjusting cushioning: a completely dynamic process that happens in real-time. The mechanism is capable of adjusting itself to various loads and speeds of the application; therefore, creating optimal and reliable performance, as well as a longer service life. • Complete solutions In the past, factories featured a smorgasbord of manufacturers, which resulted in fluctuation of quality levels as well as the lifespan of the system. The increasing cost of labour and the expense of downtime showed the importance of one supplier-one party accountability. Nowadays, there is a growing demand for a complete endto-end solution from a reputa-

ble manufacturer. Bit-and-bob purchases are still possible, but upfront investments can also prove to be worthwhile purely due to the amount of headaches prevented. • Rate of production If time is money, how can we make more time? Sadly, there is no way to physically create more time, but we can learn how to utilise it more effectively. In a factory environment, the rate of production is critical; delays can translate into millions of Rands lost. Measuring production flow and identifying problematic areas make a huge difference, and show exactly where opportunities lie (and are also lost). Pneumatic technology has evolved to a point where it can provide critical feedback about the status of a machine. Flow and pressure sensors being excellent examples of devices that can indicate a potential or current problem and even point out where these faults lie. • The amalgamation of pneumatic and electric drives Numerous pneumatic-driven factories have been required to move to the arena of electric automation. However, this doesn’t mean that pneumatic solutions are becoming obsolete, rather the contrary. Both technologies provide different advantages and by combining the best of both worlds, factories can reap the benefits. Innovative, amalgamated solutions maximise productivity, increase the output and are Enquiry no: 13 cost-effective.

March / April 2015

EC Industrial & Business News

INSTRUMENTATION, MEASUREMENT & CONTROL

Significant uptake in demand S haw Controls, a company of the Zest WEG Group, has seen a significant increase in the demand for key products such as electrical houses (E-Houses), fully withdrawable motor control centres (MCCs) and modular variable speed drives (VSDs). This has resulted in the Zest WEG Group committing to a major expansion drive at Shaw Controls as the Group expands its manufacturing capability in order to boost its presence in the local market and also in Africa, which is perceived as a major growth area. “While the Zest WEG Group is well known for distributing one of the largest electric motor ranges in the world from WEG of Brazil, our comprehensive product line up includes

switchgear, VSDs, MCCs, gensets and renewable energy solutions. We also have three fully fledged manufacturing facilities in South Africa that we are in the process of expanding as we increase our footprint in Africa,” Louis Meiring, CEO of the Zest WEG Group, says. Bevan Richards, Managing Director of Shaw Controls, reveals that next year it will embark on the design and establishment of a standalone E-House and container conversion facility. “We are anticipating a 4 000 m² facility to be able to handle these products, which represents a major extension of the Zest WEG Group’s local manufacturing capability,” Richards says. “The Zest WEG Group as a whole has the

management team and overall company structure in place to be able to handle projects of a much larger nature and to provide the customer care needed on multiple projects for different customers, and to do so efficiently and cost effectively.” In addition, Shaw Controls is in the process of establishing a centralised bulk store for the receipt and issue of all goods in line with its new inventory control system. “We are fully committed to the ISO 9001 process.” Richards says that the growth and expansion at Shaw Controls dovetails with the overall strategy of the Zest WEG Group. “We are

Optical data transceivers

ptical data transceivers are ideal for any application where data needs to be transmitted without cable and without interference, Gerry Bryant, Countapulse Controls, Managing Director, says. Countapulse Controls is the leading southern African supplier of sensing, measurement, counting, switching, monitoring and positioning instrumentation. These DDLS 500 devices from Leuze enable contact-free and wear-free optical communication wherever mechanical systems are pushed to their technical limitations. Apart from the basic function of data transmission, the DDLS 500 devices offer additional functions that simplify operation, start-up and diagnosis, Bryant notes. The basic modular design means that all functions can be arranged flexibly, depending on requirements. This means that the DDLS 500 devices offer an optimum price/ performance ratio. With real-time 100 Mbit/ second optical data transmission, all common Ethernet protocols can be transmitted without time delay over a distance of up to 200 m. The DDLS 500 devices support PROFINET, Ethernet IP, EtherCat, Ethernet TCP/IP and Ethernet UDP, among others.

Thanks to the patented singlehanded adjustment, the data light beam can be aligned precisely by one person. Convenient laser alignment is provided for by means of four laser spots for simple alignment, even over long distances. An integrated attachment plate with alignment screws makes both mounting and fine adjustment extremely easy. Clear indication of the receiving level simplifies maintenance and diagnosis, while a clearly visible status LED allows operation of the device to be monitored even from a great distance. All of the necessary functions can be combined modularly with the base model. For example, any of the following functions can be selected: heating, distances, laser alignment aid and operating ranges. Constant monitoring of the receiving level means that the user can be alerted to an impending failure – for example, as a result of excessive soiling – in good time. The prefailure message is also available as a signal on a switching output. To permit fast visual control, the DDLS 500 devices also have an LED display that is clearly visible even from a Enquiry no: 15 distance of 200 m.

Enclosure solution

ew E lec ’ s PMPT enclosure manufacturing facility, based at its head office in Pretoria, provides the ideal solution for producing fast, bespoke, plastic housings for electronic components. The process, with no need for tools or moulds, is cost effective. Prototyping and small to medium runs are all possible. NewElec’s technical consultant is in regular contact with the client to ensure immediate reaction to any alterations during the process. This results in a perfectly designed product which meets production deadline and

estimated cost factors. The basis of the production is the specially developed Planar Modular Production Technology (PMPT). Using computercontrolled manufacturing equipment, the plastic sheets (ABS, PS, acrylic etc.) are machined and chemically welded. For these exclusively milled enclosures, all housing elements are completed with either holes, slits, push-outs, depressions (e.g. keypads) or fasteners as required. All enclosures are delivered ready to install of the relevant components with no need for Enquiry no: 16 adjustments.

New precision pressure calibrators

luke’s new 721 precision pressure calibrator with dual isolated sensors for gas custody transfer applications for pressure calibration and temperature measurement, allows for simultaneous static and differential pressure measurements within a single tool. The Fluke 700G31 precision pressure gauge calibrator - a rugged, high-quality pressure gauge calibrator - delivers fast and accurate test results. It’s easy-to-use and reliable construction allows for precision pressure measurement from 15 psi/ 1 bar to 10,000 psi/690

bar with an impressive 0.05% accuracy. It is compatible with most hydraulic and pneumatic test pumps and can be combined with one of the Fluke test pump kits (700PTPK or 700HTPK) for a complete pressure testing and calibration solution. he 700G/TRACK Software allows for the upload of over 8,000 pressure measurements which are logged in the field to a table or PC. Enquiry no: 17

New 3-in-1 temperature calibrator

nstrotech, a Comtest Group company, is proud to announce their locally designed and manufactured Calog-Temp, a multi-functional temperature calibrator. It’s a high-precision, hand-held calibrator for the calibration and troubleshooting of process control instrumentation. The Calog-Temp simultaneously measures and sources ten types of thermocouples and seven resistance temperature detectors (RTD). It measures milliamps whilst sourcing or simulating millivolts, TCs, RTDs or ohms to calibrate transmitters. The Calog-Temp logging facility stores data

on the SD card supplied, which is easily downloaded to a PC via the on-board USB port and usable in most of the common spreadsheet formats. The trend feature is ideal for graphing temperature profiles and PID controller optimization with a programmable timebase. In addition, the CalogTemp has the functionality necessary to install and maintain all powered and non-powered transducers using the built-in 24V loop power supply. The Calog-Temp is an economical solution for industrial field and workshop calibration. Enquiry no: 18

integrating our product range with those of the other Group companies involved in large scale turnkey projects. This represents a huge opportunity for us to add value to our own product range by capitalising on the knowledge and experience of the entire Group.” Enquiry no: 14

Adding programmability to compact temperature transmitters

o broaden the functionality of its temperature transmitters, Turck expanded its TTM sensor line to include dynamic programmability and special features via IO-Link. These fully programmable sensors allow a user to program the temperature range required, rather than be constrained to specific ranges, for more specific temperature control. This new functionality also allows the sensor to be programmed and used as a temperature switch. The TTM sensor line includes several models, including remote-mount transmitters, transmitters with integral Class A RTDs (resistance temperature detector), as well as all stainless steel configurations to meet different measurement, space and material needs of applications. To eliminate problems associated with conventional transmitter assemblies, all of TURCK’s compact temperature transmitters are factory assembled with an overmolded or welded housing, and come ready

for installation. “These additions to our TTM line are really about providing our customers with a wide variety of options so they can have exactly what their application needs,” said Product Manager Rich Tallant. “This new offering provides a solution that is ready to plug in and play out of the box, with no terminal screws or wiring assembly needed.” The overmolded remote transmitters are ideal for applications with limited clearance because they ensure electronics stay out of harm’s way. Remote versions can also be mounted separately from the RTD, for improved temperature readings by isolating the transmitter circuitry from the temperature being measured. The stainless version offers a more robust package without an overmolded housing, ideal for food and beverage applications. Like others in the TTM line, these new sensors feature a 4-20 mA temperature transmitter. The sensors are pre-scaled 0 to 150 degrees Celsius but can easily to programmed to specific temperatures within those ranges Enquiry no: 19 with IO-Link.

March /April 2015

INSTRUMENTATION, MEASUREMENT & CONTROL

Circuit breakers

ndustrial automation customers worldwide can now reap the business efficiencies of standardising on the new global line of Allen-Bradley mouldedcase circuit breakers, and controlcircuit and load-protection devices from Rockwell Automation. The new line meets global certifications, including IEC, CE, CSA, CE and CCC. All products are RoHS compliant and feature a reduction in hazardous materi-

als. Local distributors are stocking products in more than 80 countries to ensure on time availability. Advanced selection and ordering tools aid and simplify selection for ordering the correct product in a simple, yet powerful Product Selection Toolbox, and regional configuration centres also simplify assembly, further reducing purchasing and lead times. Enquiry no: 20

Pressure transmitters for mobile applications he new PU type T pressure transmitters from ifm electron-

ic are easy and quick to connect and have a short response time of 2 ms. The units feature a resistant welded stainless steel housing, a measurement accuracy of < ± 0,8 % and a repeatability of < ± 0,05 %. With a Deutsch or Amp connector, the pressure transmitters enable a quick and simple installation. The compact units in their robust stainless steel housings only need a 19 mm width across flats.

The thin-film measuring cell directly welded with the process connection (G¼ male) is the basis for high measurement accuracy and repeatability. The PU type sensors are ideal for hydraulic and pneumatic applications with a high operating pressure. Due to their IP 67 / IP 69K protection rating, high vibration and shock resistance, good EMC compatibility and E1 conformity, this series is ideally suited for use in mobile Enquiry no: 21 machines.

EC Industrial & Business News

Next-generation temperature control

etting new standards for user friendliness, precision and performance, products in the E5_C temperature controller family from Omron reduce set-up time and provide process control that is faster, more accurate and more responsive. Key features of the E5_C line-up include Omron’s patented high-stability PID control system, and highcontrast displays that can be easily read, even in poor lighting conditions. The E5_C family is complemented by a programmable T-type controller, which allows users to design their own temperature curve by setting up to 32 different programme profiles that can contain a total of 255 segments. To cater for changing process conditions, auto-tuning can be executed automatically in every sub-segment to optimise control performance. Ramp-up, ramp-down and soak functions make the T-type controllers in the E5_C family a versatile choice for a wide range of process applications.

To satisfy all requirements with conveniently sized products, Omron is offering a full range of controllers in sizes from 1/32 to ¼ DIN, together with a slim DIN rail type that’s just 22.5 mm wide. “A major design goal for controllers in the E5_C range was to make the setting of PID parameters as easy as possible. So our patented ‘tuneand-go’ PID control algorithm allows users to optimise controller behaviour to suit their specific applications with the aid of a simple software tool, so that overshoot is minimised and maximum stability is achieved,” says Victor Marques, General Manager Omron Electronics South Africa.

merson Process Management introduces the Micro Motion Heavy Fuel Viscosity Meter (HFVM) Viscomaster, the next generation of the Micro Motion 7829 Viscomaster direct insertion viscosity and density meter. Making use of the same rugged and reliable tuning fork design as its predecessors, the HFVM incorporates a new robust low friction Diamondlike Carbon (DLC) coating that is ideal for tackling the most demanding of process applications such as marine heavy fuel oil (HFO) combustion control, marine gas oil (MGO) viscosity control and land-based fired heaters. The head-mounted transmitter is hazardous area approved and has the flexibility to connect to control systems via a wide range of digital and analog protocols.

Enquiry no: 22

System integration and startup commissioning costs are significantly reduced due to the support from 4-20mA, HART, Wireless HART and RS485 Modbus communications. The HFVM accepts and processes external signals from other field instrumentation such as temperature and mass/volumetric flow devices, enabling the meter to calculate and output enhanced process measurements while minimizing installation and cabling costs. “We designed the HFVM Viscomaster to help solve problems that our customers face on a daily basis such as maximizing engine power output irrespective of fuel quality variations, optimizing HFO/MGO cut-over times and reducing fiscal exposure through improved

NOx/SOx management,” said Andrew Sgro, Micro Motion density and viscosity product line manager. The HFVM also incorporates a new diagnostic capability called Known Density Verification (KDV) that checks the meter for measurement alarm conditions, sensor integrity and the presence of coating, erosion or corrosion. This new technology expands the availability of diagnostic information in critical viscosity and density measurement applications which can result in significant maintenance costs and cycle time reductions. Marine approvals for the meter include Lloyds, Germanischer Lloyd’s, Det Norske Veritas (DNV) and Bureau Veritas (BV). Enquiry no: 23

Measuring pulmonary function

pirometers are an essential in any occupational health testing facility as they are the primary piece of equipment used to conduct basic Pulmonary Function Tests. This equipment is often used for finding the cause for shortness of breath, assessing the effects of contaminants on lung functions, effect of medication, and progress for disease treatment. Lung diseases such as asthma, bronchitis, and emphysema can be ruled out by this test it can identify both obstructive and restrictive ventila-

tion patterns. The quality and sophistication of spirometers has improved in recent years and there are now various types and a number of different methods for measurement. These are as follows: • The pneumotachometer measures the flow rate of gases by detecting pressure differences across a fine mesh. The advantage of this instrument is that the person being tested can breathe in fresh air during the experiment. • Fully electronic spirometers

Fluke Process Calibration Range Working in a process environment such as pharmaceutical, refining or other industrial area can be challenging. Whether you’re working at a bench, out in the plant, or in the field, you need accurate tools that you can count on. Finding the right tools for the specific challenges you face every day is important. With the Fluke Process Calibration range, you can be sure that the instruments you need are accurate, best-in-class and easy to use.

Comtest Distribution 10 Enterprise Close Linbro Park 2090 Tel: 010 595 1824 info@comtest.co.za www.comtest.co.za For a FREE Demo & more INFO email: flukeDEMO@comtest.co.za

Fluke. Accurate tools you can count on.

The algorithm manages changes in ambient and process conditions, improving both machine availability and product quality. Purchasers of the Omron E5_C controllers not only get a hardware solution package but also free sales support services and the opportunity to purchase. Added to this, purchasing from a single supplier will ensure that almost all of the items needed are acquired for the control loop. Marques says that since it guarantees the right combination of controller, an actuator - which is a solid state relay or power relay, power supply, temperature sensors and multifunctional HMI (for DIN-rail mounting controllers). Web-server functionality makes remote access possible via the Internet for diagnosis and maintenance using Omron NB touchscreen terminals, which also support data logging on, for example, a USB stick.

Heavy fuel viscosity meter for marine and power applications

VSquared Marketing V2/12048/February 2015

compute airflow rates in a channel without the need for fine meshes or moving parts. They operate by measuring the speed of the airflow with techniques such as ultrasonic transducers, or by measuring pressure difference in the channel. They allow for greater accuracy as they eliminate the momentum and resistance errors associated with moving parts such as windmills or flow valves for flow measurement. They also allow improved hygiene between patients by allowing fully disposable air flow channels. • The incentive spirometer is specially designed to improve one’s functioning of the lungs and the peak flow meter is useful for measuring the ability of a person breathing out air. • Windmill-type spirometers are used for measuring forced vital capacity without using water and has broad measurements ranging from 1000 ml to 7000 ml. It is more portable and lighter than traditional watertank type spirometers. • The AME tilt-compensated spirometer can be held horizontally while taking measurements but should the patient lean too far forward or backwards the spirometer’s 3D-tilt sensing compensates and indicates the patient position. • The whole body plethysmograph gives a more accurate measurement for the components of lung volumes as compared to other conventional spirometers. A person is enclosed in a small space when the measurement is taken. Regardless of the type of equipment used, all spirometers must meet with American Thoracic Society (ATS) and European Respiratory Society (ERS) standards for range and accuracy. Quality Control checks of the equipment should be carried out at least daily before testing begins. Enquiry no: 24

March / April 2015

EC Industrial & Business News

FOOD & BEVERAGE

High performance conveyor components B are ideally suited for conveying in food and beverage applications, are available in straight running, side flexing and specialty models that offer improvements in noise levels, coefficient of friction, corrosion and energy consumption.” Speciality stainless steel grades and high quality plastics are used in the manufacturing process, which means these chains offer high wear, mechanical and corrosion resistance, excellent dry running capability and an optimised, flat conveying surface. This range is available in a flat, and rubber top plate design, as well as the low back pressure series, in widths from 3-1/4” to 12”. Material selections for specific applications include standard acetal resin (LF) for general purpose conveying, extra performance acetal resin (XPG) for lower friction and the New Generation NG polyester resin for lower friction and extended service life.

Last eight stands at food and beverage expo

frica’s Big Seven (AB7), the biggest food and beverage expo on the continent, has almost completely sold-out all exhibition space at the multi hall Gallagher Convention Centre – with no further room to expand – for the first time in 13 years. AB7 takes place at Gallagher Convention Centre, Midrand from 21-23 June 2015. “There are only eight stands left, and I would love to see some dynamic South African companies grab these stands at Africa’s biggest food and beverage trade expo.” says John Thomson of show organiser Exhibition Management Services. “For some inexplicable reason, AB7 2015 has started off with a real ‘bang’ With four

months still to go till show time, we have been inundated with enquiries from trade visitors all over the world wanting to register to attend AB7,” adds Thomson. “In addition to the thousands of visitors from 44 countries that regularly attend, we have had calls from potential new visitors in Finland, Greece, Cameroon, Canada, Egypt, Israel, Jamaica, Jordan, Saudi Arabia and Sudan taking the total up to 55 for now”. “The biggest misunderstanding of Africa’s Big Seven is that South African companies and manufacturers see it as a domestic expo, when in fact, it attracts more international visitors than other events in Africa. There’s a long list of regular South African exhibitor companies that have enjoyed excellent business from making international sales at the show,” says Thomson. At last year’s AB7, visitors reported there were not enough exhibitors of manufacturing equipment, baking equipment, coffee products, health products, packaging equipment, and wine producers, and catering equipment at the show. “If you are a South African producer of any of these products, AB7 is the perfect platform to showcase your business and products to regional and international buyers.” Enquiry no: 26

Software facilitates project information flow

EA Process Engineering South Africa has introduced GEA-Assist, the Group’s browser-based information sharing programme, to its clients locally. This online information exchange facilitates streamlined access to project information for all approved individuals, regardless of location. Improved plant performance and increased productivity is acquired through tracking maintenance costs, preventing asset failure and extending asset life. The programme caters for storage and retrieval of all necessary communication. Project documentation and piping & instrumentation diagrams (P&ID) can be uploaded,

Custom-engineered NG material provides high strength, optimum wear resistance and reduced pitch elongation. A feature of this material is its efficiency in “no lube” applications, due to its low coefficient of friction properties. NG high performance chain also ensures sustainable water and energy reductions. Other features of this range, which ensures safe and efficient food handling, include reduced noise levels, easy cleaning, low maintenance requirements and extended service life. Included in this range of conveyor chains for the food and beverage sector are straight running chains, magnetic side flex chain, chains with rubber pads, gripper chain and snap-on plate chain. Multiflex chain and crate conveyor chain also form part of the System Plast range Enquiry no: 25 of conveyor chain.

New scales for basic industrial weighing tasks

ven basic weighing E tasks require precision in production environments.

Miscounting, inaccurate weighing or incomplete orders can cost businesses in money and reputational damage. Mettler Toledo can help businesses avoid those unwanted situations with its cost-effective basic scales. Industrial Basic Scales combine the manufacturing quality and weighing expertise that Mettler Toledo is known for with the simple and easy-to-use functionality of a production tool. This new line of scales offers all of the features required for accurate weighing without all of the unnecessary extras that can drive up cost. The Industrial Basic Scale line comprises the following products:

• Basic portioning scales for fast, mobile food weighing • R eliable checkweighers for food and manufacturing applications • Rugged floor scales and pallet-weighing solutions for logistics and warehousing applications, and • Reliable basic counting scales for accurate order picking, packaging and completeness checks. Industrial Basic Scales come with stainless or mild-steel weighing platforms, easy-to-read terminals and secure overload protection. All scales are intensively quality tested and adhere to the required industry standards. Most of these options are available through Microsep in this country. Enquiry no: 28

Geared Motors \ Drive Electronics \ Drive Automation \ Industrial Gears \ Services 1THREAD_7186_EAS

MG’s light materials handling division distributes an extensive range of quality branded products for conveying in the food and beverage sector, including System Plast’s high performance conveyor components. “The System Plast range consists of flat top stainless steel and plastic chains, sprockets, bearing supports, structural components, brackets, magnetic curves and straight running tracks, designed specially for conveying systems in beverage applications,” says Ryan Forsyth, divisional manager of BMG’s light materials handling division. “The System Plast chain product line is divided into two main categories: engineered plastic chains typically for beverage and nonlubricated applications and stainless steel chains for glass-handling, heavy duty or abrasive applications. “System Plast plastic conveyor chains, which

The hygienic choice from SEW-EURODRIVE

as can 3D models, plant layouts and time schedules. Provision for plant operations and maintenance has also been made, in fact, all information pertaining to an entire project, including comprehensive product information, is available to authorised personnel. The service includes email alerts when files are uploaded and queries answered, drastically reducing the number of necessary phone calls and email correspondence. Specific categories make the site userfriendly. ‘Document Hosting’ incorporates the most up-to-date plant data, including assets and any current projects, all of which are Enquiry no: 27 stored in current status.

The food and beverage industry demands an especially high level of hygiene. Our DAS series’ smooth surface provides the perfect solution for hygienic production areas because they are easy to clean and are designed to prevent dirt build-up. The unit prevents the formation of germs and bacteria and offers resistance against essential cleaning processes, including the use of aggressive cleaning agents and disinfectants. Let us ensure the highest level of hygiene for your industry.

SEW-EURODRIVE - Driving the world.

Tel: +27 41 372-2244/6 Web: www.sew.co.za

New compact controller

itsubishi Electric introducM es the FX3S programmable logic controller – the new entry

level model for the proven FX3 series. Notable attributes of the FX3S PLC are its flexibility and expandability. It allows users to choose only the functionality necessary to perform a specific application, saving on hardware costs. The PLC provides full function PLC control, built-in high speed inputs and outputs, available relay outputs, and multiple, builtin communication ports. It also includes expansion options for communications, analogue and temperature control. As part of the FX3 series, the FX3S can use

March /April 2015

FOOD & BEVERAGE

many of the existi n g programming resources that are available for other FX3 series PLCs. This greatly reduces time and costs for system setup. The PLC is designed to handle basic control tasks, such as simple positioning or analogue, and temperature control operations that do not require complex control tasks. The compact PLC is especially well suited for food and beverage applications, as well as material handling, and fan and pump applications for irrigation and building automation. Enquiry no: 29

Infrared technology

eeping production strictly on schedule in any facet of the food and beverage industry – whether it’s pumps, conveyors or electrical connections - means downtime is not an option. Comtest, Fluke’s local representative advocates including infrared inspections (IR) into the maintenance mix. Their range of high performance, thermal imagers makes year-round spot-testing possible, on-site, specifically troubleshooting and monitoring transformers, switches, disconnects and MCCs; pumps, motors and compressors; valve operation; tank and sludge levels; level control performance; pipe blockages and integrity; operating temperature; conveyors and roller bearings; boilers and chillers; HVACR; and roof moisture, air leaks and insulation issues. By performing quick infrared spot checks, maintenance tech’s can uncover potential failures, thus allowing for timeous repairs when convenient. The line can be kept moving by frequently scanning and troubleshooting critical equipment. Traditional troubleshooting using trial and error can be effective, but time consuming and costly. What is critically important,

is to pinpoint an issue within a mass of sprawling production lines, quickly, because every second of downtime is expensive. Equipment cost has historically forced plant managers to outsource annual infrared inspections, and in many cases, limit the scope of work. Annual scans certainly uncover problems, but users shouldn’t have to “hope for the best” until next year’s scan. Food and beverage production demands reliability, so yearly spot checks just aren’t enough. The production line monitor can narrow down and rule out possible problem-causes faster by seeing the whole picture with infrared, allowing varying temperatures of components to tell the ‘inside’ story. Quick Tips for performing successful IR inspections: 1. Ensure consistent frequency: Extra to troubleshooting, infrared inspections of all major components and connections should be performed at least bi-annually. 2. Adjust for emissivity: Components and materials emit their energy differently. For accurate findings, ensure that the proper emissivity setting is being used for the material

Motorised torque arms

earings International, part of the Hudaco group of companies and a distributor of premium bearings and power-transmission products and equipment to Southern African industry, supplies the Dodge range of motorised torque arms (MTAs). The MTA mechanical drive range provides a heavy-duty solution for any bulk materials handling application that requires a shaft-mounted reducer. They are predominantly used in the quarrying and aggregate sectors but are equally at home in the coal, iron-

EC Industrial & Business News

ore, wood and sugar industries. According to Bearings International’s Bearings Manager, Ross Trevelyan. “This tried-and-tested product offers a host of important cost saving benefits and enjoys wide acceptance within our local market.” The fact that the Dodge MTA units enable any brand of IEC B5 flange motor to be used with the reducers adds to the product’s popularity. “We noted a steady increase in

that is being inspected. Also, consider altering the surface by adding tape or paint to increase emissivity. 3. Perform qualitative measurements: Compare findings with similar components and connections under similar conditions to reveal thermal anomalies. 4. Ensure safety during inspection: Beyond electrical safety, be careful not to neglect the surroundings while performing infrared inspections. Focusing too heavily on the thermal imager can distract the personnel from rotating, cutting, or other dangerous equipment. Enquiry no: 30

demand for the units over the past two years and in September 2014 the MTA range was extended, initially available in sizes 2, 4 and 6, to include sizes 3, 5, 7 and 8. This has enabled us to offer customers the complete MTA mechanical drive range from 1.5 kW to 75 kW, based on output speed and a service factor of 1.4”. The Dodge range includes the traditional torque arm branded series (the belt driven Dodge Torque-Arm II shaftmounted reducers) and the motorised Enquiry no: 31 MTA unit.

Diffuse reflection sensors for wet areas

he compact O6 WetLine photoelectric sensors from ifm electronic are now available with IO-Link. The resistant stainless steel housing with IP 68 / IP 69K protection rating ensures reliable use even under severe conditions. The units feature an interference-immune background suppression. Even in the event of steam, smoke and highly reflective environments, the automatic sensitivity compensation guarantees reliable operation.

The clean round light spot in the operating area ensures a consistent light distribution in the light cone. Scattered light around the light spot is avoided. The compact O6 WetLine is perfectly sealed. The two setting potentiometers are fitted with a double seal. The front panel and the potentiometers

are flush embedded to allow residue-free cleaning. These compact powerful units can also be supplied as through-beam and retroreflective systems. The O6 WetLine sensors with the IO-Link interface allow the user to set the range, sensitivity, light-on / dark-on mode, switching delay or deactivation of the Enquiry no: 32 operating elements.

GRAMEC-FORBERG MIXER

THE TWIN SHAFT MIXER WITH WEIGHTLESS ZONE GIVES YOU: Short Mixing Time

In many cases, as low as 10 seconds and an average mixing time of less than 1 minute

Small or Large Batches Mixers are manufactured in 14 sizes from 7 litre to 7000 litre batch capacity. Batch levels from 30% to 100% of nominal

Versatile For Liquid Addition Small or large amounts of liquids with high or low viscosity can be added to powders, granules or pellets

Please contact us for more Information, video DVD or test runs on your products

Complete Homogeneity High precision blending with a coefficient of variation regularly below 5%

Electricity Savings

Up to 60% saving because of low power input and extremely short mixing times

Gentle Product Handling It even mixes breakfast cereals without breakage

GRAMEC (Pty) Ltd P.O. Box 89380, Lyndhurst, 2106. 7 Brighton Road, Bramley View Ext.6, Johannesburg, South Africa. T:++27 11 882 1914, F:++27 86 615 1547, http://www.gramec.com E: gramec@gramec.com or torb@gramec.com

March / April 2015

FOOD & BEVERAGE

EC Industrial & Business News

Pallet free bulk-bags food handling T he locally manufactured Tellap pallet-free packaging system - which is a strong, lightweight alternative to a conventional bulk bag and wooden pallet - is ideal for safely handling agricultural seeds and grains, as well as food commodities and ingredients. “Tellap is an environmentally-friendly palletfree bulk bag that does not require fumigation or heat treating, which is necessary for conventional external pallets,” says Ken Mouritzen, MD, Tellap. “This innovative system integrates two lightweight plastic sleeves into a polypropylene bulk bag, replacing the conventional wooden pallet, with a totally recyclable design.” “An increasing number of leading bulk bag storage and transportation companies are investing in the cost effective Tellap system and are benefiting from reduced shipping

costs, fuel savings, lower warehousing costs and ISPM15 compliance. An important feature in the food sector is that Tellap pallet-free bulk bags ensure a clean and safe environment.” A regular wooden pallet weighs about 25 kg, while each Tellap sleeve weighs only 1,5 kg, which means freight and disposal costs are reduced. These bags, which are rack compliant, also offer improved space utilisation in warehousing, rail cars and trucks. They can be stacked three high in a container or four high in a warehouse and can be safely loaded and unloaded by one forklift operator. This system, which has specialised protective tine guards, allows standard forklifts to lift bags securely from their base sleeves or top loops, reducing the chance of damage. There is also no need for an additional worker to

hook the bag onto the forklift. Sleeves increase safety, efficiency and stability. Sustainability is also critical in a modern product handling system. Tellap is made of polypropylene and is 100% recyclable to avoid waste. Tellap, which is certified by TEN-E Packaging Services, global specialists in packaging component testing, has passed rigorous independent testing and meets stringent performance requirements for non-dangerous goods contained in flexible intermediate bulk containers (FIBC). This international certification and Tellap’s in-house controls, ensure every customer consistently receives a safe quality product fit for every specific packaging purpose. The Tellap system is ideal for packing and transporting resins, food commodities and

Determining an optimal air motor solution

owson and Dobson is a market leading supplier of a comprehensive range of world-class industrial products and after-sales service solutions, and is an authorised Southern African distributor of the internationally-recognised range of Deprag air motors that are ideally-suited for local use in demanding operations such as food and beverage preparation. According to Deprag product manager for air motors, Dagmar Dübbelde, from the initial selection of a drive, a designer must make careful considerations when looking for the optimal motor. “The selection of an air motor is not difficult. However, when focusing on pneumatic systems, there are numerous factors that can decisively influence the power of the motor.” Deprag offers a simple six-step guide in selecting the most effective air motor, particularly for pneumatic applications. • Selection of the drive system. Air motors are available in diverse design options, and their application and intended operating time are of great importance when selecting the basic principles. “An air vane motor is suitable for regular running cycles. In comparison, gear motors and turbines are maintenance-free and therefore better suited to continuous operation.” Says Dübbelde. • Construction material An inexpensive cast iron air motor is suit-

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able in a dry surrounding atmosphere and in standard stationary production. In the food industry, air motors must be able to withstand cleaning agents and steam. The Deprag Advanced Line motors with external parts made from stainless steel are additionally sealed and lubricated with food industry standard USDA-H1 grease. Pneumatic drives can even be operated underwater, but water depth must be determined. Motor power Using the formula: nominal torque times working speed, divided by 9550, the theoretically required power in kW can be calculated. Integration of the motor Deprag boasts comprehensive spindle designs and individual fixing methods, which work out more cost-effective than separate gear solutions. Within the Deprag motor range there are numerous air motors with integrated planetary gears, spur gears and worm gears. Integration is concluded with the technical verification of the maximum permissible axial and radial load on the drive spindle of the air motor. Durability Adherence to the framework conditions determined during the design phase and compliance with the instruction manual will ensure the longest possible life of the drive. Purchase price and running costs Operating costs are just as important as the initial purchase cost to determine long-term cost. Dübbelde highlights that fact that the operating costs are determined by the air consumption. “The right choice of motor sets the course for low running costs. The closer the motor runs to nominal speed (50 percent of the idle speed), the more efficiently the air is used,” she concludes. Enquiry no: 34

ingredients (including cereals and nuts) as well as pharmaceuticals, minerals and chemicals. Tellap has patent approval from authorities in South Africa, Europe, Asia, Australasia and the USA. Enquiry no: 33

Best practices when buying coding and labelling machinery

hen considering buying coding and labelling machinery for an efficient production line, it goes without saying that a ‘penny wise and pound foolish’ approach will simply not suffice. The fact of the matter is that, sometimes, these miscalculated decisions can lead to serious financial repercussions for the business. The purchasing of coding and labelling machinery is no small feat for a business and in today’s fast paced environment where ‘time is money’ the ability to reduce costs in production lines, have efficient machinery and saving on uptime of equipment can all be determined in the initial purchasing decision. While many businesses opt for the less expensive alternative to buying coding and labelling machinery, it can save the business money in the short -term but often ends up

costing more in the long-term. The capital outlay of the machinery can seem extravagant at first, but there is a lot to consider when making the cost of ownership decision, which justifies the initial capital outlay for the business, which includes: • Consideration of the total cost of ownership before making the investment • Ensure that the service provider has a national footprint • Avoid the cheapest capital outlay options • Consider the future of the business The ideal solution is Pyrotec’s PackMark division, which is the sole South African distributor of Markem-Imaje’s range of machinery and printing solutions, as well as A.L.Tech and Harland Machine Systems. “With more than 45 years of experience, PackMark is able to assist our clients with world class coding and labelling equipment and our advanced product offering, outstanding service and fully equipped workshops enable our clients to run their businesses optimally”, says Brandon Pearce, General Enquiry no: 35 Manager at Pyrotec PackMark.

March /April 2015

EC Industrial & Business News

COMPANY & PRODUCT PUMPS, VALVES, PIPES NEWS & FITTINGS

Comprehensive valve solutions V alves form an integral part of Weir Minerals Africa’s total solutions package for the mining and minerals processing and general industrial sectors, and the company offers two valve brands, namely Isogate valves and BDK valves. Isogate valves are ideal for abrasive applications in mining and minerals processing. Applications range from base metals (copper, nickel, iron) to precious metals and gems (gold, silver, platinum and diamonds) and industrial minerals (phosphates, talc, kaolin, silica and clays). These valves provide a cost-effective solution for on/off, throttling and reverse flow controlling of flowing media in industrial processes that involve abrasive or corrosive materials. These range from sand and gravel to dredging, water and waste water, food collection, preparation and processing, coal-fired power plants, pulp and paper mills and shot and sand blasting equipment manufacturers. The slurry valves feature ease of

maintenance and low total cost of ownership as the main design criteria. “Conventional valves are only designed for liquid service and therefore seldom produce satisfactory results when applied in abrasive and/or corrosive slurries,” he notes. Typical problems include rapid wear of valve seats and liners, sticking and leakage to the atmosphere during operation. They can operate under wide pressure and temperature ranges, while sleeves are available in a variety of materials, from natural rubber to EPDM, nitrile or neoprene. A unique feature that is on offer is Weir Minerals’ proprietary abrasion resistant Linatex premium natural rubber liners. Isogate MP (mechanical pinch) valves utilise a flexible rubber-lined pinch sleeve that is collapsed between two mechanical bars for accurate modulating control, positive closure and drip-tight shut-off. Isogate PP (pneumatic pinch) valves are pneumatic or hydraulic

Name change reflects significant product portfolio expansion

actuated enclosed body pinch valves ideal for remote operation using typical plant air and do not require auxiliary cylinder operators. Isogate heavy duty slurry knife gate valves combine a low maintenance design with a range of materials for diverse applications. The particular focus here is abrasion resistance. The BDK valve range is ideal for general and specialised industrial applications. These range from power generation to oil and gas, petrochemical, steel, fertiliser, pharmaceuticals and water treatment. The BDK valve range encompasses ball, butterfly, gate, globe and check valves, as well as diaphragm, knife gate and plug valves. Enquiry no: 36

atson - M arlow Pumps Group announced last month that it has changed its name to WatsonMarlow Fluid Technology Group to better reflect the evolution of the company from its roots as a manufacturer of peristaltic pumps and tubing, to its current position as a world leader in fluid path technology. Watson-Marlow Fluid Technology Group, which has a global network of operations including seven factories and 28 direct sales offices, is part of the Spirax-Sarco Engineering Group plc . The company now encompasses seven distinct brands which, combined, deliver a complete suite of fluid technology solutions to the biopharmaceutical , chemical process, food and beverage, mining and environmental market sectors. The name change follows the recent acquisition of BioPure, which signaled the company’s strategic move to offer a wider range of solutions to the biotechnology and pharmaceutical markets. Commenting on the name change, Watson-Marlow Fluid

Etanorm is a classic that keeps getting more efficient. It meets the energy efficiency requirements of the ErP Directive for 2015 already today – for three good reasons: optimised hydraulic components for pace-setting efficiency, individual impeller trimming, and ideally matching drives and automation components. Etanorm is available really fast, comes in numerous variations, and provides the unique reliability of a globally identical product. For more information, please visit www.etanorm.com / www.ksbpumps.co.za

erman technology company Kobold Instrumentation, manufactures a polysulfone paddle to monitor flow for nominal pipe sizes greater than NW 32. Applications include the monitoring of cooling circuits, dry running protection for pumps, prevention of low water levels, monitoring pipe fractures and the monitoring of lubricant circuits. Fluid flow, regardless of direction, deflects the paddle and moves a magnet

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(EBD) configuration and drywell bearing housing is ideally-suited for the aeration process. “It allows for much higher radial and axial forces to be absorbed by the gearbox, while the drywell bearing housing ensures no oil can leak into the sensitive water treatment process.” Inenzo Water projects manager, Chris Erasmus adds: “In our industry, we must ensure that we offer clients top solutions at competitive prices. Over the years, we have found that the pricing, quality and service offered by SEW-Eurodrive played a decisive role in our procurement for this project.” Griffiths indicates that SEWEurodrive has extensive application knowledge with regards to gearboxes driving aeration equipment. “By listening to the client’s requirement and understanding the unique problems faced on this project, the company was able to marry its own extensive product range and knowledge with the expectations of the client.” One of the key advantages in selecting the MC series of IG units is that they are assembled by SEW-Eurodrive in Nelspruit. Local assembly cuts down on international shipping costs, which results in savings for the Enquiry no: 38 client.

Polysulfone paddle flow monitor

Pumps Valves Service ■

Enquiry no: 37

Making a splash

he aeration process at the Stellenbosch municipal water treatment plant in the Western Cape has been dramatically improved after ten worldclass modular compact (MC) industrial gear (IG) units supplied by SEW-Eurodrive were installed by water project specialist, Inenzo Water. The MC units can handle from 6 to 65 kNm of torque and can be universally mounted. One of the initial and most critical stages of water treatment is to aerate large volumes of water in treatment plants. Aeration is the process whereby water is enriched with oxygen through a continuous rotation and churning process. This enables the release of harmful gases from the water and kills certain bacteria. It also hastens the breakdown of organic matter in the water. Aeration is usually achieved by rotating a large propeller through the water volume, thereby mixing air into the water. This propeller is exposed to huge radial and axial forces, and if the drive gear is incorrectly installed, it can lead to failure and damage to the propeller and the gearbox driving it. SEW-Eurodrive Cape Town branch manager Byron Griffiths (pictured) notes that the company’s extended bearing distance

Here’s a big reason you can save even more energy.

Technology Group’s President, Jay Whalen, said: “Our new name unifies our growing portfolio of fluid path technologies, it is an expression of what we deliver today, and a reflection of the growing portfolio of businesses and opportunities that sit within our group. Our sector market focus, combined with the recent acquisition of BioPure gave us the opportunity to rethink the way we present ourselves to the market. We can no longer simply be defined as a pump or tubing company: we now offer customers a much more holistic offering”. The company name change is part of a five-pronged growth strategy, which includes targeted investment in selective product development and market sector diversification. This is highlighted by the additions of MasoSine (sinusoidal pumps for the food and beverage sector), Flexicon (filling and vial capping systems used in the aseptic filling sector), BioPure (single-use tubing connection systems as used in the biopharmaceutical sector) and non-pump transfer tubing development.

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holder fitted to a permanent magnet. The magnet actuates a dry-reed embedded switch in the switching tube. The paddle switch is available with N/O contact or N/C contact. The inlet and outlet pipe section should be approximately three times the nominal size of the piping. The flow monitor can be fitted in a standard T piece or reducing pipe. Ideally the flow monitor should be fitted in horizontal piping. Enquiry no: 39

March / April 2015

EC Industrial & Business News

PUMPS, VALVES, PIPES AND FITTINGS

Factors affecting cyclone performance T he most common process factors that affect Dense Medium Cyclone (DMC) performance can be mitigated by understanding the operation of a hydrocyclone, as well as the overall Dense Medium Separation (DMS) process. “Early identification of problem areas means that appropriate solutions can be formulated, which is where the experience and expertise of Multotec comes to bear,” says Ernst Bekker, Cyclone Product Specialist. Dense medium separation takes place where particles of differing density fractions are separated via a medium that has a density between that of the two fractions. Particles with a lower density will float, while particles with a higher density will sink. The aim is to minimise the quantity of non-valuable material in the targeted fraction while maximising the recovery of the valuable fraction. The feed in a hydrocyclone consists of water and solids, which enters the cyclone tangentially to produce a spiralling motion. Due to centrifugal forces, the coarser particles migrate to the outside wall of the cyclone and move downwards towards the spigot

or apex. The finer particles move to the centre of the cyclone and are removed through the vortex finder into the overflow. Due to the inverse ratio of solids and water in the outgoing streams, a high slurry density is produced in the underflow and a low slurry density in the overflow stream. The same separation process applies to the medium used inside the DMC, with the medium split mainly being influenced by the ratio of spigot to vortex finder diameter, the operating head and medium characteristics. As a result, density gradients form throughout the length of the DMC. The

differences in medium density values between the feed, overflow and underflow streams are used to calculate the differentials inside the DMC. These are important parameters in defining the medium behaviour inside the cyclone and can be used for early identification of possible process related problems. Cyclone suppliers have incorporated larger inlet designs in their product portfolio to allow for higher capacities and larger particle top sizes to be accommodated. “The drawback of these designs is that the retention time of particles inside the cyclone is reduced, which can have a negative impact on separation efficiency if it is a difficult separation. Therefore particle top size, which impacts on the cyclone inlet opening, plays an important role in determining the correct cyclone diameter, in addition to the throughput that must be accommodated,” Bekker says. The inclusion of a barrel section in the DMC depends mainly on the difficulty of separation. This allows for more residence time inside the cyclone due

New for pump and dampener maintenance

lowrox, recently announced the launch of the Flowrox Expulse, designed to assist during pump and dampener maintenance by reducing noise and vibration associated with traditional methods—which can lead to pipe damage that can cause breakage and a loss of revenue. Already known as a leader in the manufacture of industrial valves and pumps, Flowrox is an authority in the industry when it comes to pipe dynamics and its extensive knowledge and experience are applied into every new product design. The Flowrox Expulse was designed for use by companies in the Oil & Gas, Mining, Metallurgy, and other industries where pipes and valves are used to move materials or fluids using pressure—and Flowrox’s reputation in these industries covers multiple product lines and solutions.

Traditional pulsating pump dampeners are known to produce unbalanced shaking that can result in failure or operational drawbacks, which in turn require additional add-ons and devices to counter its challenges. Engineering innovation and ingenuity have helped Flowrox design a complete solution for this effective pulsation dampener system, which quiets noise while settling pressure peaks and ensuring a continuous fluid flow. One of the most noticeable features on the Expulse is the product’s ability to reduce energy consumption in your operation by up to 10 percent, largely as a result of its absorption of up to 90 percent of pulsations. In addition, the device’s reduction in the hammering of the pipeline and pump can lead to extended operational lifetime for the pump bearing and gearbox—two critical compo-

nents in pipeline operations that face wear and tear in high-performance environments. “A shutdown due to a threat to pipe integrity can not only be costly, but hamper the ability to generate revenue for clients who depend on this type of equipment,” said Todd Loudin, President of Flowrox. “Our company has designed the Expulse to help reduce the chance of pipe damage and breakage in a costeffective manner.” The robust solution offered by the this flexible pulsation dampener prevents the collection of sediment, particles or residue thanks to its built-in self-cleaning operation—further adding to the benefits of ease of installation and care-free maintenance. Enquiry no: 41

Error-free field pressure tests on PVC pipelines

he field pressure test is used to test the integrity of the pipe joints which were completed on site. This test is covered by the SANS 2001:DP2 – Medium pressure pipelines standard. Although the standard attempts to lay down the rules thoroughly, it is often misinterpreted or misunderstood. DPI Plastics has developed a ‘how-to’ guide on field pressure testing to ensure that the integrity of a pipeline is not compromised. Anyone performing a field pressure test should inspect test equipment beforehand to ensure it is calibrated and leak free. When pressurising the pipeline, take into account the location of the pressure gauge and any static head that may add to the test pressure. The pipes also have to be properly backfilled to keep them from rising up from the trench during testing. It is important to keep the joints exposed, to make inspection for leaks easier and quicker. Pipelines can be several kilometres long, and it is beneficial to test in sections. This is more accurate and takes less time to inspect the joints. It also requires less water and is quicker to fill the line. The reason for performing the pressure test is to establish that the pipe-

due to differences in static head in the test section. Test procedure

line does not leak. The test pressure must be 1.5 times the working pressure of the pipeline, up to a maximum of 10 bar. Above 10 bar, the test pressure must be the working pressure of the pipeline plus 5 bar. This refers to the working pressure of the pipeline, not the pressure class of the pipe. A pipeline with an operating pressure of 16 bar should be tested at 21 bar (16 bar + 5 bar). The mistake is often made to test all pipes at 1.5 times operating pressure. In this case, the difference between the correct pressure and a 1.5 times operating pressure (24 bar) is 3 bar. The test pressure must be between 1.25 times and 1.5 times the operating pressure at any point in the pipeline,

Fill slowly, preferably from the bottom and remove all air from the pipeline. Check the position of pressure gauge (static head), and pressurise slowly. Check for movement at stop ends. Once the line is at test pressure, inspect the pipeline for leaks. Once the test time has elapsed, commence ALR test. Test for another hour, checking the volume of water needed to maintain test pressure. ALR can be calculated as follows: 0.01 x OD mm x test length km x √test pressure MPa. Eg. 500 m of 250 mm Class 16 PVC pipe = 0.01 x 250 x 0.5 x √2.1 = 1.811 litres. The test duration is three hours for pipes of nominal diameter 400 mm and above, and between one and three hours for pipes of nominal diameter below 400 mm. Another hour is needed to perform the allowable pressure drop test. If the pipeline fails the pressure test, the leak must be located, repaired and the test repeated. All air must be bled out of the pipeline before repeating the test.

Enquiry no: 42

to its larger internal volume. However, correct selection of the DMC does not mean that the unit will perform correctly. “OEMs constantly look at ways to improve their designs, but these improvements are only effective if the process itself is optimised,” Bekker says. The dense medium process consists of various process streams and pieces of process equipment, which can influence the DMC performance if not optimised, for example magnetic separators. “Operational personnel sometimes do not realise or understand these dynamics.” A decrease in top size results in a finer mean particle size fed to the DMC, which can impact the separation efficiency if the

cyclone selection was originally not designed for that type of material, while an increase in top size can increase the risk of blockages at the cyclone inlet. “The effect of decreasing or increasing the top size needs to be verified with the cyclone OEM,” Bekker cautions. “Proper DMC maintenance, in addition to metallurgical audits, may be one of the most important factors to help ensure optimal DMC performance. This is often neglected due to inaccessibility or time constraints,” Bekker says. Excessive internal wear creates grooves inside the DMC, leading to turbulent flow patterns, which can cause misplacement of particles. Enquiry no: 40

March /April 2015

PUMPS, VALVES, PIPES AND FITTINGS

EC Industrial & Business News

No more fugitive valve emissions V alve live-loading systems are complicated. Most require the use of torquemeasuring tools and incorporate a disc spring stack that is often too long for the available bolt length. As a result, valve bolts usually need replacing. Now, British multinational Aesseal has launched LiveStar, a new-generation live loading system designed to be compact without requiring extra bolt length to accommodate the uncompressed disc spring stack. LiveStar has been designed as an encapsulated disc spring configuration with defined compression length to automatically adjust the gland and maintain constant pressure on the valve packing set. It is likely to find a major market in control valves installed in environmentally sensitive

over-compressed, hang up on threads or shift asymmetrically on the bolt. Further, LiveStar needs no new bolts fitted to the valve to accommodate the system. The extended nut is screwed onto the existing valve bolt. Other features include compensation for thermal expansion of the valve and flange parts, optimum and predetermined compression set by the dimension of the spring housing, protection of the spring set from dirt and outside contaminants, and sustained maintenance of a constant gland load and sealing force. Available for all standard metric bolt diameters from 8mm to 27mm and Imperial UNC from 5/16” to 1”, from Aesseal branches and Enquiry no: 43 distributors throughout Africa.

Increased range of vacuum solutions

tlas Copco Compressor Technique has introduced a new portfolio of vacuum products that can support the specific vacuum needs of customers for many common vacuum applications across a range of market sectors. This pioneering vacuum technology follows on the extended vacuum solutions portfolio for rough and medium vacuum introduced in 2014. In addition to the new range of 2-stage oil-sealed rotary vane vacuum pumps, Atlas Copco also unveiled a new range of mechanical vacuum booster pumps, rotary piston pumps, liquid ring vacuum pumps as well as steam ejectors. This new portfolio can support

applications such as those found in petrochemical refineries. The system fits on existing gland bolts and is tightened on installation until the visible assembly gap closes. During operation, this closed gap serves as an indicator of valve packing wear or consolidation, either or which will cause the gap to reappear, whereupon the assembly is simply retightened to its optimal set point. No torque wrench is required. A major advantage of the Aesseal design over other live-loading systems is that the disc spring, which is encapsulated against environmental impact by an outer cylinder, slides on an even, machined surface rather than on a bolt thread. The disc spring can therefore never become

the mining, cement, paper, refineries and food sectors as well as industries as diverse as aerospace, automotive, refrigeration, glass, bottling, canning and woodworking. The new GHS VSD+ Series is a highly efficient vacuum pump with Variable Speed Drive (VSD). Feature and benefits of this range include energy savings of around 50%; quiet operation; sustainable productivity due to built-in efficiency and reduced environmental impact due to ultra-high oil retention at all operating pressures. The GVD 0.7-28 Series deliver excellent ultimate vacuum pressure, high pumping efficiency and superior vapour handling capabilities with quiet operation. The GVD 40-275 Series of are renowned for their high ultimate vacuum, rapid pumping

speeds, quiet operation and ability to handle water vapor. These direct drive rotary vane pumps are inherently compact and vibration free; the finger-proof fan and coupling housings offer excellent operator protection. The ZRS 250-4200 mechanical booster pumps are based on the simple rotary lobe principle and remain the preferred pump for applications where high pumping speeds are required for pressures in the region of 0.01 to 50 mbar. This pump must always be backed by another pump, which can deliver against a high-pressure differential to atmospheric pressure. Operating at relatively low pressures, the mechanical booster pump is not exposed to the same concentrations of corrosive process media as is the backing pump, which makes it highly reliable. Liquid ring vacuum pumps are offered as standard packages in a number of configuraEnquiry no: 44 tions.

Heavy duty submersible slurry pumps

ntegrated Pump Technology of South Africa has supplied 20 Bravo 900 submersible slurry pumps and 20 M20 control panels to Kamoto Copper Company in the DRC. These heavy duty electrical submersible slurry pumps are the largest of their kind in the Grindex product family, says Klint Bawden, General Manager: Sales & Marketing, Integrated Pump Technology. Chris Heunes, Export Sales Manager, Integrated Pump Technology, explains that the company’s products are being deployed at three different areas of Katanga Mining’s operations in the DRC. “Our Bravo range has proved particularly successful for Katanga Mining, which has been using Grindex products for three years now and has about 300

pumps in operation.” Heunes says that EC Mining has been formally appointed as the distributor for Integrated Pump Technology for the DRC and is in the process of establishing a fully-fledged service and repair workshop at Kamoto Copper Company to cater for its aftermarket needs. “Pumping slurry is one of the most demanding applications for any pump, due to such issues as sediment build-up leading to costly downtime and repair costs,” Bawden explains. “The Bravo range from Grindex is robust and hard working enough

to result in reduced operating and maintenance costs.” These pumps, with a maximum submersible depth of 20 m, do not require any support superstructure, which makes for quick and easy installation and less space needed for their operation. The cartridge seal is preassembled for quicker and easier mounting, while the Hard-iron impeller and pump housing feature high wear resistance, which is critical in slurry applications. The large throughlet means that the pump can handle solids of varying sizes. Enquiry no: 45

Best in class lead times for pumps in EMEA

aton recently announced a significant investment its manufacturing capability in EMEA that will enable the company to meet industry-leading delivery times for its X20 pumps range. Eaton’s X20 pumps are used in wheel loaders, agricultural vehicles and road sweepers as well as other mobile and marine applications. The investment of more than €2.4 million will enable the localisation of a regional assembly and test programme for X20 piston pumps at the Eaton Havant UK site, with the aim of providing customers with a ‘best in class’ delivery lead time across Europe, the Middle East and Africa. Commenting on the announcement, Mark Foreman, plant manager, said, “We are expecting to see an upsurge in demand for open circuit piston pumps in the next few years as the manufacturers of original equipment increase production to meet their orders. Normally, this would mean that lead times would increase for products such as the X20 pump but this investment means we can actually reduce lead times to approximately half that which is industry standard now.” Rick Jacobs, president of Eaton’s hydraulics business for EMEA commented on the announcement saying, “This news will offer a huge advantage to Eaton’s customers in EMEA. By significantly reducing lead times on the X20 pumps we will play a major role in helping manufacturers fulfil their order books and the quality and robustness of our technology, plus our ability to provide a global after-sales support network, gives companies across EMEA a Enquiry no: 46 superb choice.”

Process plant steam control

ndustrial boilers normally produce steam at high pressures and temperatures, since in this superheated condition it carries more energy and results in more efficient production of power in the turbine. This high pressure also allows the steam to be transported around the plant in smaller lines with less heat loss. For use in a process plant, both the pressure and the temperature have to be reduced. A letdown station solves this problem. It comprises a pressure reducing valve and the temperature reducing apparatus. The solution is to use a valve with a special trim that is engineered to solve the complex requirement of both pressure reduction and noise control. A Mitech energy dissipating disk stack that fits into the company’s range of standard Globe valves is one of the best methods to achieve this. The pressure is dropped across many stages. The disk stack combines the concept of many restrictions in series (along each passageway) with multiple paths in parallel (several passageways in each disk and many disks in a stack). This enables the valve to handle low flow rates as well as the maximum flows. One or more diffuser plates may be installed downstream of the valve to create back-pressure to enable a smaller valve to be used. Reducing the pressure of the superheated steam achieves very little in reducing the temperature. To reduce the temperature of the steam a desuperheater is utilised to add water to the superheated steam. To vaporise the water a large amount of energy is required to overcome the latent heat. The high temperature steam provides this. The result is an increased flow of steam at a reduced temperature. By varying the amount of water added, the temperature can be controlled. Enquiry no: 47

March / April 2015

PUMPS, VALVES, PIPES AND FITTINGS

EC Industrial & Business News

Potable water treatment solution for small and medium cities V

eolia Water Technologies has improved the design of its Opascep Pack in order to meet the new challenges faced by public authorities. Opascep Pack constitutes a range of skid-mounted systems which turn surface water into drinking water in compliance with the World Health Organization’s (WHO) recommendations. Ready-to-connect, the systems combine wellknown and efficient technologies on a single skid: coagulation, flocculation, lamella clarification, pressure sand filtration and disinfection. The modular design allows larger treatment capacities up to several hundreds of m³ per hour.

Ex-stock split-case pumps M ather+Platt’s new horizontal split-case centrifugal pumps, launched last year at Electra Mining, are soon to be held in stock to eliminate the lead time on new orders currently taking between six and eight weeks to deliver. The planned stockholding will result in immediate delivery throughout central and southern Africa of several popular models within the range of more than 150.

The new split-case range is tightly niched, comprising single-stage and two-stage models delivering duties up to 15000m³/h. Mather+Platt’s two-stage U-series is designed for lower duties, and features a single suction, twin volute casing design to transfer the flow medium at between 20m³/h and 600m³/h. For the high duty market, the single-stage double suction

LR-series features a closed type impeller to deliver duties from 10m³/h to 2200m³/h in either horizontal or vertical execution. A sister single-stage series, the larger LN-range, delivers duties of between 400m³/h and 15000m³/h. Pump casings can be manufactured in cast iron and stainless steel, or cast in exotic materials such as super duplex. Impellers can be supplied in cast iron, stainless steel or bronze.

The range, seven models, can treat larger flow-rates from 10 up to 125 m³ per hour (100 m³ per hour previously). Tank height was increased thanks to the use of Hi Cube containers during transport, allowing for higher flow-rates and an overall increase in settling and filtration performances. The settling part is now equipped with the latest generation of reinforced LVE 100 lamella blocks, which lightens the structure supports and reduces overall fabrication lead time by up to one week for the larger models. Full automatic mode is now available as a pure standard, while manual operation remains available as an option. Opascep Pack is a cost-effective solution because it does not require heavy civil work: a simple reinforced concrete slab is enough to install it. Assembled and tested in France before delivery, they have short lead-time and can be quickly installed on site (10 to 15 days depending on the model).

Horizontal split-case pumps carry the significant advantage of allowing maintenance without having to disconnect the pump and remove it from the pipeline. Other advantages include balanced axial loading, high efficiency, low noise and vibration, and the ability to operate at almost shut-off capacity without excessive deflection. With scheduled gland packing changes and routine maintenance, Mather+Platt’s pumps are expected to achieve an average useful life of at least 20 years. They have applications in industrial and municipal water supply, water and

Enquiry no: 48

wastewater treatment plants, cooling and hot water circulating systems, injection water, spray ponds, irrigation and general industry. A notable feature of Mather+Platt’s support for the range is its offer to modify standard models to fit the requirements of specific applications, for example fitting different pump internals to deliver an altered performance within a specified pump dimension. The new range is expected to further enhance the Mather+Platt brand, which in South Africa has been synonymous with pumps since Enquiry no: 49 1954.

Maintaining Africa’s pumps

dvanced after sales systems enable KSB Pumps and Valves to maintain a massive fleet of pumps in tip top working condition wherever they have been sold and installed throughout Africa. No matter the age, make or model of the pumps, as long as it bears

the KSB name the company undertakes to ensure spares and services are available on short notice throughout the continent for the duration of the pump’s life. Having sold hundreds of thousands of KSB pumps over the past six decades, the important task of supplying after sales services is undeniably one of the most important services offered by the company and is prioritized throughout each division as a result. According to KSB Pumps and Valves aftermarket sales manager, Andreas Gremels, as a first-choice supplier of pumps for important applications such as bulk and municipal water authorities, power stations, petroleum refineries, mines, irrigation schemes and industry, the company has also

introduced advanced condition monitoring equipment to assist customers with preventative maintenance and optimization of pump systems. KSB’s advanced SES Efficiency System is able to do a complete energy efficiency analysis, detect variations in flow rates, vibrations and other clues that it interprets and analyses in real time to optimize pumping systems and assist with the scheduling of appropriate preventative maintenance to ensure the least disruption on liquid transfer systems. Simultaneously, field staff and service personnel are able to assist customers with the operation and maintenance of pumps anywhere on African soil. Depending on the size and scope of the pumping operation KSB Pumps are able to make available framework agreements in regards to service, repairs and spares. Enquiry no: 50 “

Specialists in Corrosion Protection

HotDip Galvanizing – 3m x 1.2m x 1.8m Thermal Zinc / Aluminum Metal Spraying

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Globe valve adept at control tasks

he universally compatible GEMÜ 536 globe valve has a robust design and is reliable in operation. This valve was developed with a long service life and low maintenance requirements in mind. The GEMÜ 536 pneumatically operated 2/2-way globe valve has a low maintenance membrane actuator which can be controlled by inert gaseous media. The valve plug is fixed to the spindle in such a way as to allow flexing during closure in order to ensure tight shut off. Steel and PTFE as well as a fibre glass-reinforced PTFE version are available as seats. The valve spindle is sealed by a selfadjusting gland packing. This provides a lowmaintenance and reliable valve spindle seal even after an extended period of operation. The wiper ring which has also been introduced additionally protects the gland packing from contamination and damage. The customer has a choice between cast stainless steel 1.4408 or SG iron GGG40.3 (available from the beginning of 2015) for the material of the valve body. A flange in accordance with EN 1092 or ANSI cl. 125/150 RF is available for the pipEnquiry no: 51 ing connection.

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March /April 2015

EC Industrial & Business News

HYDRAULIC & PNEUMATICS

Axle and wet brakes gear oil

uchs Lubricants Titan Utto ZF is a specialised UTTO (Universal Tractor Transmission Oil) for ZF axles with limited slip differentials and axles which operate under high thermal conditions as experienced in the mining and construction industries in Africa. Titan Utto ZF improves wear protection and at the same time reduces noises and shudder in wet brake systems. It has been extensively tested by a prominent manufacturer of

construction and mining equipment and, based on the product performance, Fuchs was requested to supply over 600 000 litres to be marketed on their private label over the last three years. This product helps to ensure the correct functioning of wet brakes/locking differential systems even under continuously high loads, reduces the operation noises of the wet brake/locking differential system and protects against wear and corrosion. Enquiry no: 52

Rippers for mini excavators A

newly designed line of Cat rippers is now available for mini hydraulic excavators to meet diverse tasks that include picking, grabbing, sorting and digging in varied ground conditions for applications such as landscaping, demolition, site preparation and the installation of underground services. These specialist work tools are purpose-built for fitment on a broad spectrum of Cat mini excavators, as well as on original equipment manufacturer machines in the same class. Ripper operating weights extend from 45 to 107 kg, depending on the machine model match. For added versatility, Cat rippers

can be used with a pin grabber coupler, coupler and thumb, or as a pin-on attachment. The curved shape allows the ripper to work in conjunction with existing thumbs. “When used with the Cat Dual Lock pin grabber coupler, rippers can easily be interchanged with Cat buckets for on-site rip and load multitasking,” explains Barloworld Equipment product specialist, Craig Christie.

Rippers are manufactured from highly durable materials to match arduous operating conditions. For example, the gussets on the top bracket are designed to withstand side load; whilst the high strength alloy shank further extends wear life. Three ground engaging tool (GET) tip options are available: penetration, sharp centre, and heavy duty abrasion. “Choosing the right GET tip will be determined by the applicaEnquiry no: 53 tion,” Christie adds.

Servo-driven plasma cutting table

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T X C F H E L B D E O K D I A U Z I R A L U L G M H Y D R A Y C T W Y

L E Q N C D X S S C E G V D S L N Y D U W T T B W Q R D B O R C B A H

H X C T E G P K F O O E P Y N N I Z O T L R T I O A A R Q M E B C Y J

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P G H P N E U M A T I C N F R H U Q N G N I V L O S H J M G Y F Z L Y

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P B W T O K T J W X D F W N G M S I U Z A V Z L E A D E R S E T Z P C

ectra Automation recently supplied and integrated the drive componentry for the first bevel head servomotor-driven CNC plasma cutting tables manufactured by CNC Clear Cut. The Bosch Rexroth servo drive train, which interfaces with the CNC control through the Ethernet-based SERCOS 3 communications protocol for real-time machine response, provides an enhanced cutting accuracy and throughput for superior threedimensional metal profiles. “The high-end plasma cutting tables have used traditional servo motors in the control of the cutting axes,” comments Paul van Niekerk, CNC Clear Cut. “While these motors were fit for purpose, they did not have the accuracy, speed and controllability of the Bosch Rexroth servomotor with integrated

SERCOS 3 communications.” Apart from being the supplier of the servomotors, servo drives and planetary gearboxes, as well the aluminium profiles for the torch bridge, Tectra Automation integrated the drive train, including engineering, programming, coding and fine tuning. Tectra Automation sized the servomo-

tor requirements according to the torque, speed and inertia specification of each machine cutting axis. “The servo system with integrated SERCOS 3 protocol improves machine output, enhancing production, productivity and quality of the finished product by providing an instantaneous instruction relay between the CNC control and the servo system across SERCOS 3,” explains Georg Venter, Divisional Manager, Electric Drives and Controls, Tectra Automation. “SERCOS 3 also offers a high immunity to electrical noise, which, given the electrical nature of plasma generation, was an invaluable aspect of attaining a more precise, higherquality plasma operation,” he says. Enquiry no: 54

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March / April 2015

EC Industrial & Business News

AGRICULTURE Fuel management system benefits farmers

Increasingly the farming community is going to need a reliable and convenient system they can use in order to comply with SARS legislation which requires them to have a comprehensive log book detailing their personal and business Diesel usage in order to get Tax rebates. “In collaboration with the farmers and using our Piusi range on management and dispensing fuel equipment, we have developed a complete management system. This includes a dispensing pump operated with a tagging system that permits pre-selected users to enter vehicle information and the quantity of the diesel required, and allows this information to be exported in customised reports to a computer,” says Warren Erasmus Managing Director Meter Systems. The beauty of a good fuel management system is that it not only controls and keeps track of fuel distribution and consumption, but it also adds to

the bottom line by decreasing fuel and labour related expenditures. For each fuelling transaction, this fuel management system will identify both operator and vehicle and keep track of the fuel usage, eliminate spillage and allow for tight fuel inventory management through reconciliation of fuelling transactions, totalizer readings, and tank levels. Farmers can then print this recorded information in the required SARS format and submit for their Diesel Usages and refunds as required. Meter Systems is a division of the Set Point Group and has been supplying Fluid handling equipment to the Petrochemical Industry for over 30 years. It offers a diverse range of flow meters, dispensers and Management Systems for controlling and monitoring almost any fluid.

Enquiry no: 55

Proven quality for longer service life

TIHL’s speciality Rapid Micro Harvester Special (RMHS) saw chain has been designed for professional applications under the toughest of working conditions, the RMHS saw chain has been developed to withstand the continuous high loads which are a standard element of highly mechanised timber harvesting operations. In comparison to standard saw chains, harvester saw chains are subject to extreme conditions such as a driving power greater than 30 kW, high chain speed and being pinched in the cut. High loads result in cracks radiating from the rivet holes that finally cause the chain to break. The stressful conditions of continuous high loads experienced during professional harvesting operations exposes the individual parts of the harvester chain to constantly alternating tensile forces that can cause cracking and breaking of the chain. Now, with the RMHS saw chain, all parts of the chain have been specially strengthened to vastly

reduce the risk of cracking while maintaining the usual high cutting capacity of all STIHL harvester chains. This increased durability adds value through longer service life and less chance of downtime. Cutting results from a professionally used harvester depend largely on the design and power of the drive unit, the condition of the guide bar, and the working technique. The guide bar and saw chain have to do the heavy work of actually cutting and so have the greatest impact

on the machine performance and final results. STIHL manufactures saw chains especially for the demands of professional wood harvesting operations. Extensive R&D has proven the ideal material mix for every component, and with meticulous maintenance, the RMHS speciality saw chain will ensure less friction for smoother operation and a resultant increased wear period. The RMHS is a semi-chisel chain with slim, straight-sided cutter. The offset depth gauge of 1.0mm makes this a very smooth running chain, so that the chance of chain breakage is minimised. The sliding surface has been increased through the patented asymmetric shape of the toe and heel, resulting in considerably reduced pressure on the cutters and hence the longer service period. The saw chain is marked with the letters HS on the cutters and an arrow point on the tie straps to show the direction of rotation. Enquiry no: 56

Food production the theme at congress

eeding a population of over nine billion people by 2050 is one of the most daunting challenges facing agriculture during this century. This is one of the crucial issues to be addressed at this year’s FERTASA (Fertiliser Association of Southern Africa) congress, says Mr. Adam Mostert, CEO of Fertasa. Therefore the theme for the congress is “Food production for a growing population in Southern Africa”. This coincides with the United Nations “2015 International Year of the Soil”. “Substantially more plant nutrients will be required. It is estimated that by 2030 the current requirement of 10kg/ha will increase to 50kg/ha. The

question is how much food must be produced by that time to meet the demand? How is it going to be produced? Do we have sufficient land and water? These are the crucial issues that need to be addressed,”

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Mostert emphasised. The 55th annual congress of Fertasa takes place on 13, 14 and 15 April at the Lord Charles Hotel, Somerset West. Specialised speakers from different branches of agriculture will address the congress, including Dr Guy Scott, former minister of agriculture and acting president of Zambia, Prof. Nick Vink, chairman of the department of agricultural economics, University of Stellenbosch and the Agricultural Writers’ Agriculturalist of the Year 2013, and Prof. Ferdi Meyer, director food and agricultural policy, University of Pretoria.

Workplace wellness programme

hree new farms in the Sundays River Valley region have joined the AIDC EC Wellness Programme which is improving the lives of Eastern Cape farm workers. Nine hundred workers from San Miguel Farm, Habata Boedery and Penhill Farms have joined the programme which provides workers with world leading wellness as well as HIV&AIDS information, resources and support. A key feature of the programme is the appointment and training of peer educators or farm employees, who ensure that wellness is addressed on the farms in a sustainable and professional manner. San Miguel Farm, Habata Boedery and Penhill Farms grows the reach of the programme and adds to the network of existing farms. In cooperation with Luthando Farm, SRFT (Sundays River Farming Trust) and SRCC (Sundays River Citrus Company), the AIDC EC last year facilitated comprehensive Health Risk

Assessments on five farms in the Sundays River Valley. Representing a total of almost 600 farm workers, the farms are passionate about improving health and wellbeing of their workforce. Workplace Wellness Programme Manager Arnelle Heynes said 90% of workers at contracted farms chose to take part in the Wellness Days, and more than 70% volunteered to take an HIV test to know their status. Each worker was invited to see a nurse who could offer several health tests to choose from: HIV Counseling and Testing, TB Screening, Glucose and Blood Pressure Measurement as well as BMI (Body Mass Index). Farm workers and management are convinced that Wellness Days are essential services to their workforce. “We are aiming to achieve a 100% uptake, so that each worker can know their status und take responsibility of their lives.” says Zelda van Tonder, Accreditation and Training Coordinator at SRCC. Enquiry no: 58

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Enquiry no: 57

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March /April 2015

EC Industrial & Business News

COMPANY & PRODUCT NEWS

Pre-cast bridge deck planks

he needs of architects and civil engineering contractors for specialised construction products and materials change as infrastructure projects become more technologically advanced

while at the same time having to remain cost effective. Rocla, part of the IS Group, South Africa’s leading manufacturer of precast concrete products, is geared up to offer innovative solutions no matter

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how challenging the customer requirement is. Rocla recently received a request for pre-cast deck planks for installation on the recently constructed Colchester Bridge. The N2 was being converted into a double lane highway due to increased traffic to the region and a new bridge was required by SANRAL. The new Colchester Bridge was built parallel to the existing bridge which crosses over the Sundays River and took six months to complete. Graham Howell, Sales Consultant for Rocla, Port Elizabeth said “This was the first time Rocla had been tasked with supplying these pre-cast bridge deck planks, but upon receiving the specifications, we made specially designed moulds. Once the moulds were ready (approximately 8-12 weeks from order) we started the

pre-cast plank production, which comprised 2,640 planks of 2150 x 300 x 75 in size”. “Rocla’s sophisticated and strategically located manufacturing plants ensure that our customer’s requirements are fully embraced, even if the contract calls for non-standard newly designed product. Concrete product expertise and guidance has always been the cornerstone to our success and this was evident with the Colchester Bridge project where the supply of pre-cast concrete planks was a new venture for us, but having seen the successful installation of the pre-cast planks, we are now able to supply this product

to other bridge related construction projects, and tailor the design of the planks to meet requirements” said Howell. Rocla recently designed concrete cabins to meet the requirements of enclosing sensitive and expensive electrical equipment at photovoltaic farms. They have also manufactured underground concrete water tanks for water preservation and storage. Enquiry no: 59

Parts distribution centre enhanced Innovating and delivering successful staff outsourcing solutions since 1972!

PC Storage Solutions SA recently completed a turnkey storage solution installation for a new 7 500 m² national parts distribution centre to be used by a large Japanese motor vehicle manufacturer in Midrand, Gauteng. The tailored solution had to replicate the company’s strict global logistics standards and procedures for the storing and distribution of its automobile replacement parts, and be completed within just 26 days. “While the new warehouse had to comply with stringent design and safety parameters in terms of how each product type is stowed, we were still able to suggest and implement certain customised stowage procedures to tailor the solution to the unique requirements of the South African operation,” explains Fred Albrecht, Managing Director, APC Storage Solutions SA. The inventory, which consists of the complete range of automobile parts and accessories for distribution to all

local dealerships and service centres, is shipped regularly from Japan in special containers which are then divided into large parts, small parts and airbags – each being catered for with an item-specific storage solution. The 4 200 m² large parts area was fitted with eleven rows of customised conventional pallet racking, all barring one of which is back-to-back, with wooden decking on each level designed to carry maximum loads of 600 kilograms. The racks have a max-

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imum length of 39 metres and consist of five levels giving a total height of nine metres. Specialised dividers were manufactured and installed to support the various part dimensions and a unique in-rack sprinkler system in line with ASIP safety standards was installed to protect the stock in the unlikely event of a fire. The small parts area of 750 m² is a two-tier mezzanine system for maximum utility of available floor space. Connected via a gangway system, this section was fitted with Simplos shelving and also houses the high value stock in a dedicated area that is fenced off and access controlled. 25 000 specialised, variously-sized cardboard storage boxes and barcodes were designed, manufactured and installed for both the large and small parts areas for a more effective inventory management, with the entire warehouse run by a state-ofthe-art warehouse management system that identifies the correct logistics Enquiry no: 60 for each product item.

-CAT Environmental Solutions is an official supplier of Telesto’s EXTINGUISHmist – a handheld water mist fire extinguisher able to suppress all common causes of fire without collateral damage to property, humans, animals and the environment. According to I-CAT non-executive director Professor Jan du Plessis, “This has the potential for enormous cost savings. Using conventional equipment, only five percent of water directed at the fire actually applies to extinguishing it. The remaining 95% floods the surroundings. With the EXTINGUISHmist, a superfine ‘dry to the touch’ mist is emitted that quickly vaporises in the fire zone.” Comprising simply of de-mineralised water, the mist is also 100 percent human, animal and environmentally friendly. Du Plessis explains: “Other fire suppressants, such as foam, dry chemical powder and CO² are toxic, causing harm to humans and animals, destruction to property, and pollution. The EXTINGUISHmist, on the other hand, is an ideal neutral and is so safe that it can be sprayed directly onto victims threatened by fire, allowing responders to swiftly and effectively execute rescues.” Response time is the main factor determining the extent of a fire’s damage to life and property. Du Plessis points out that EXTINGUISHmist’s universal application across all common fire classes not only accelerates fire incident response, but also reduces the need to carry multiple types of Enquiry no: 61 equipment.

March / April 2015

COMPANY & PRODUCT NEWS

EC Industrial & Business News

Caution a priority in generator purchase

ly-by-night generator dealers are doing harm to consumers and the generator industry as a whole. This is the opinion of Tom Bloom, GM of Smith Power Equipment’s Power Products division, distributors of the well-known Kipor brand of generators. “At this time in South Africa when there is an unreliable electricity supply and the generator market is experiencing an unusual surge in demand, there are many chance-takers who see generators as a way to make a “quick buck”, says Bloom. “These people often do not have the experience or the expertise to give the right advice and, most importantly, are not able to give the requisite backup service.” He adds that generators are often used for backup for vital services and

bought on price considerations alone. Cheaper initial cost often leads to the most expensive overall experience. Check the company carefully. Is their product excellent, do they have an excellent service record, do they have the knowledge about your particular needs? If you can tick all these boxes then it is most definitely worth paying a premium at the beginning!” says Bloom. He adds that the proof of the pudding is in the fact of how many generator companies went out of business after the last load-shedding cycle. Enquiry no: 62

New reliable end milling concept oroMill Plura Heavy C Duty (HD) is a completely new solid end milling concept, developed for removing large amounts of metal in a short amount of time and to provide the reliability needed for heavy roughing. CoroMill Plura HD is the first choice solid roughing end mill for shoulder milling, full slot milling, ramping and helical interpolation in steel and stainless steel. It can also be used with cast iron and heatresistant materials. The tools offer secure and reliable machining in a wide range of cutting parameters. High process security and

a long predictable tool life are essential in heavy roughing operations. The optimized flute shape was especially designed as a result of a Finite Element Analysis, and it assures effective chip evacuation when machining with a large depth of cut. This flute design also prevents re-cutting of chips and sudden tool breakage. By efficiently removing chips, full slot milling up to two times diameter with fiveteeth end mills is possible without compromising process security. Enquiry no: 65

Local company offers global solution

ncreased load shedding and endless electricity price hikes continues to haunt South Africa. A recent statement by the Democratic Alliance (DA) estimates that, since 2008, load shedding has cost the country R 300bn and 1 million jobs. “The sad reality is that the current situation will get a lot worse, before we see any improvement,” says Ryan Steytler, energy expert and Director, The Sungrid Group (In2Brands). Involved in portable (solar) power, The Sungrid Group (In2Brands) are focused on providing viable and alternative solutions to the South African consumer. “Eighty years ago the con-

a lack of understanding of the product, poor service and maintenance levels and an inability to react quickly in an emergency can have dire consequences. “Time and again we are called to generator installations to help out where the service from other suppliers has been dismal and the story is always the same – “we thought we were getting a bargain because the unit was cheap.” “A generator is not an item to be

cept of harnessing the sun’s energy hadn’t been imagined. Today, we are putting the sun’s energy in your pocket,” continues Steytler. Its latest offering, Solsave, offers consumers a full range of alternative energy choices comprising both smaller and heavier portable off-grid power options. Its flagship offering, the Solsave my-powa, a solar power bank making use of the latest Sun Power Cell (SPC) technology, is able to quickly generate power with a world record efficiency panel.

A mere 10 hours of direct sunlight provides enough power to charge all essential devices including phone, tablet, camera, MP3 player, eReader, GPS, action cameras and smart watches. “But the real beauty is that for those who choose, Solsave’s my-powa can also be charged via a conventional wall plug (USB wall charger) for maximum convenience,” says Steytler. Early 2014 saw the rollout of its ‘Switch to Portable Solar Power’ campaign, focused on providing the country (and Africa) with reliable, costeffective and environmentally friendly Enquiry no: 63 energy alternatives.

Loaded container handler delivered

LT SA, which supplies and supports a wide range of material handling equipment used in diverse industries, has recently delivered a loaded container handler to Transnet Engineering. “This robust machine – the Taylor THDC-955 – is being used in Pretoria to handle heavy ISO 20’ and 40’ containers, which have been loaded with high value engines and manufacturing components,” says Charity Gumede, marketing director, BLT SA. “This container handler, which has a rated capacity of 42 000 kg, will significantly improve operational efficiencies on site and will all also increase the overall full container storage capacity at the plant. “Operators are impressed with the

chain suspended spreader that allows for easy handling and improved driver comfort. The shock, which normally

travels through the machine when handling heavy loads, is absorbed by these chains. “The Taylor THDC-955 has enhanced safety features, including forward and reverse motion alarms, wide angle rear view mirrors, as well as hand rails and anti-slip steps. Axle mounted spring-on, air-off parking brakes, with a brake saver system, prevent the operator from driving through the parking brakes. “The mast pivot housing has a two piece bolt-on design for easy and safe service removal and the dual flow system prevents a load from falling in the event of a hose failure. This series also has an emergency lowering valve system.” Enquiry no: 64

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March /April 2015

INDUSTRY PEOPLE

Developing young welding talent

ir Products South Africa, sponsor of the South African Institute of Welding’s (SAIW) Young Welder of the Year, sees the competition as another opportunity to further its aim of investing in the youth of this country. The company’s corporate social investment (CSI) strategy has long been focused on education and training initiatives, especially in areas where there is an urgent need for skills development. “Welding skills are critical in many industries and it is no secret that there is a dire shortage of engineering skills worldwide, specifically when it comes to expert welding. It is our great pleasure to have provided welding gases to facilitate this competition in the various areas of welding,” says Josua Le Roux, General Manager: Central Support at Air Products South Africa. The company has been closely involved with the Young Welder of the Year competition since its inception in 2004. For this year’s competition, which was held from the 26th to the 30th January 2015 at SAIW’s premises in Johannesburg, Air Products provided various

specialist gases including argon for TIG welding and its special blends: Coogar 82 for MIG welding and Fluxblend for flux-core welding. In addition, Air Products also made a contribution towards accommodation and other costs related to the competition. “We are passionate about training, skills development and the empowerment of young people in South Africa,” says Le Roux. “It is our hope that the use of Air Products’ range of specialist Air Products South Africa sponsored the 2015 Young Welder of welding gases and the expe- the Year competition. Not only does this annual event resonate rience in taking part in this with the company’s focus on skills development in young people, event will have an extremely but with the particular need to develop welding skills in industry. positive impact on the future careers of these young welders.” with our focus on skills development in young “It has been our pleasure and privilege to people, but we recognise welding as a soughtsponsor the Young Welder of the Year competi- after skill in industries around the world,” Le Enquiry no: 66 tion. Not only does this annual event resonate Roux concludes.

EC Industrial & Business News

Industry Movers International Consulting Engineering Company Royal HaskoningDHV has appointed Salani Sithole as MD for its South African operations with effect from 1 March 2015.

Francois Sieberhagen has been appointed PE Branch Manager SEW-EURODRIVE

Building classrooms for a better future

uzuki Auto South Africa, in conjunction with its advertising agency, Penquin, recently funded the construction of two classrooms at a rural school near East London. The Bulugha Primary School serves some 160 learners from the surrounding farms and settlements, but as is the case with so many smaller rural schools, is seriously lacking in resources - despite the best efforts of its dedicated principal, Matthew Madwara. While his resolve to create a school on the foundations of discipline and response is evident in the positive, willing attitude of the teachers and the learners, one of the many issues facing the school is the shortage of space. Until recently, Grades 1 to 3 had to share a classroom, as did Grades 4 and 5, making it very difficult for teachers to provide learners with the dedicated, grade-specific attention they need and deserve. Recognising the plight of the school, Suzuki Auto SA last year agreed to fund the construction of two additional classrooms in conjunc-

tion with Bottles 2 Build Schools, an initiative aimed at addressing the shortage of school classrooms nationally. The classrooms are built using an innovative eco-friendly construction method based on interlocking plastic bottles, resulting in sturdy, well-insulated structures that can be erected

quickly and cost-effectively. Construction of the two classrooms at Bulugha Primary commenced in late November last year, and by mid-December, the classrooms had been completed, ready to receive the 2015 intake of learners. The new classrooms will transform the life of the children at the school, and the ability of its teaching staff to educate them efficiently. "Following the launch of our new, spacious and versatile Ertiga in the Eastern Cape last year, we became aware of the plight of the learners at Bulugha Primary," says Yukio Sato, managing director of Suzuki Auto SA. "Assisting in relieving that plight by funding two classrooms has been a particularly satisfying experience. However, there are many other schools facing a similar shortage of facilities. "We would like to urge corporates seeking to support a worthy cause of national importance to consider investing in the future of the country by assisting in ensuring that our learners have access to the school facilities they so urgently need," Sato concluded. Enquiry no: 67

Sithandile Ngxangxa, from Mcobothini in the Eastern Cape, is changing his life with a Masters in Analytical Chemistry bursary from REDISA (the Recycling and Economic Development Initiative of South Africa)

Automatically managing To-do-Lists

usy people find smarter ways to do things, quicker and often more effectively. But not everyone can multi-task or remember everything that needs to be done, which often causes stress and therefore less effective output. An example of the need to manage multiple requests, track and then follow-up on queries, is the customer service department. As one of the key business trends set to shape 2015, and an example of where hundreds if not thousands of requests are processed every day/month, smart technology can be a lifesaver. Task Express, developed by Cape based Khanyisa Real Systems (KRS), has been effective in streamlining multiple tasks, routing them to the correct person and as a result, increasing the response time, helping organisations create satisfied and happy customers in the process.

“With more and more c o m p a n i e s automating the contact page on their websites, we felt there was a need to construct a simple but sophisticated programme that could manage query flow and route these immediately to specific mailboxes” commented Brent Blake, Project Director at KRS. In being able to

respond quickly to a customer, without the need for that customer to go through several referrals before getting to the right person, organisations using Task Express or others like it, have noted improved customer confidence and an overall boost in company reputation. The list builder and task scheduler are easy to use and eminently scalable – from the individual ‘coffice’ worker to large companies (with multiple branches) handling large volumes of management tasks. Far more than a task tick box, listing programme, Task Express allows users to collaborate online (via the website) – allowing managers to see in realtime, what employees are doing and literally ‘be on the same page’ and can also be accessed from anywhere. Enquiry no: 68

Warrant Officer TF Gwe (left) from KwaZakhele Police Station in Motherwell, Eastern Cape, was recently awarded the prestigious SAPS National Woman of the Year Award at the second annual National Service Excellence Awards Ceremony which recognizes and honours excellent performance by members of the SAPS, reservists and members of the Community Police Forums.

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