Kzn industrial & business news issue 89 by The Media & Events Company

ISSN NO: 1562 -5702

October / November 2014

R20.90 (incl. VAT)

A first for FMCG in Sub-Saharan Africa

he beginning of September saw the first ten colour gravure printer of its kind in SubSaharan Africa commence production at the Nampak Flexible facility in Pinetown. As a result the company can now offer an ever wider spectrum of printed flexible packaging options for film, paper and foil laminations. According to Anand Padayachee, General Manager for Nampak Flexible, what sets the Heliostar SL 10 apart is that it offers a ten colour print option, in a market that has previously been limited to a maximum of eight. It is believed that this new addition will give the company a pronounced marketing edge in the packaging industry. Nampak Flexible has not seen investment in gravure printers for 15 years and this new technology, will definitely give the company a good marketing edge. The process was initiated a year ago, with the identification for a need to purchase a new machine and involved research across the offering of multiple world leaders in the field. This turnkey project with Windmőller & Hőlscher was signed in August 2013.

ith its second edition, the KZN Infrastructure Funding Fair has established itself in the business calendar by helping to raise more than R7 billion for key infrastructure projects in the province. Hosted earlier this month by the KZN Treasury and professional services firm Deloitte, about R22 billion worth of projects were pitched at the event. “The event brings together pro-

The state of the art Heliostar GL gravure printer The machine arrived in the country in July 2014 and was up and running by the first of September. This was ahead of time and well within budget. The German made machine sets the cost effective standard for flex-

ible packaging applications, with a maximum printing speed of 400 m/ min achievable on most designs. The electrostatic print assist works through the core of the impression roller and improves ink transfer to the

Inside

substrate. This, working in conjunction with the unique ink roller positioning - developed for better ink flow and transfer, allows for quick re-filling of the gravure cells ensuring that ink residue has no time to dry out. In this way colour intensity is maintained during printing. State of the art drives without mechanical transmission ensure maximum register accuracy during production and re-register setting is quick and easy, resulting in optimisation of waste and set up time. A fully automatic turret unwind and rewind station allow for splicing at maximum running speeds. All of these features ensure a machine capacity of 80 million meters per annum. “It is refreshing to have the new technology and the capacity to remain globally competitive” explains Gerald Chotu, Operations and Technical Director. “The markets have been tough, margins have been down and there has been real pressure to improve manufacturing costs. This technology brings a huge benefit to the company and the industry in general”.

Tim Madgwick of KZN Treasury says the funding fair helps government keep track of infrastructure and can especially help municipalities attract funding for their projects. Water and road infrastructure were top of mind at this year’s event with the 18 proposed projects presented. “Investors want big ticket projects which guarantee a return on

International company expands into Cato Ridge - page 3

Materials Handling, Bulk Handling & Logistics - page 7 Plastics & Rubber page 22 Chemical & Allied Industries page 23

Enquiry No: 1

KZN Funding Fair proves its mettle by raising R7 billion ject promoters and funders to start engaging in conversation” said Andre Pottas (pictured), partner and Regional Corporate Finance leader at Deloitte. Pottas,, pointed out that the event helped project promoters to package their projects in a way that makes them bankable and increases their attractiveness to funders. One way of doing this is to package projects as a cluster.

Issue no. 89

investment,” Pottas said, adding that the Infrastructure Funding Fair filled an important gap through the creation of Public Private Partnerships (PPPs) which complemented the limited resources of government. “This enables acceleration of infrastructure development, the

Heating, Cooling & Ventilation - page 24

Green Industries & Renewable Energy - page 28 Company & Product News page 32

continued on page two

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October / November 2014

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KZN Industrial & Business News

Western Aqueduct progressing well

t least 35 percent of the break pressure tank that is under construction in Ashley Drive, Hillcrest, has been completed and the project is likely to be finished by the second quarter of 2015. A spokesman for Icon Construction – which was awarded the R45-million contract in May this year – confirmed that they had finished the blinding layer for the floor of the massive reser-

voir and poured the first wall panel by the end of August. On completion, the Ashley Drive break pressure tank will hold 20 mega litres of water. A second break pressure tank which will hold 20 mega litres will be constructed in Wyebank. The tender for this project is due to go out in the fourth quarter of this year with construction expected to commence at the beginning of 2015. These are an integral part of the 39 km second phase of the Western Aqueduct (WA) which is currently under construction between Inchanga and Ntuzuma. The first phase of the Western Aqueduct was commissioned at the end of 2012 and together they form the biggest ever bulk water pipeline project undertaken by EWS. The estimated overall cost of the second phase of the WA and associated branch pipelines is R 1.8 billion in present day terms. The WA is intended to both replace and augment existing infrastructure

that brings water from the Midmar and recently constructed Springrove Dams into Durban. It is ultimately expected to inject up to 400Ml per day, significantly strengthening the capacity of bulk water supply and meeting the needs of the greater eThekwini region for the next 30 years. To date, approximately 15 percent of the second phase of the WA has been completed. Although the entire second phase is expected to be completed within the next seven years, work on the four contracts that are already underway is running according to schedule and key components of this vital pipeline would be complete by 2017. The Western Aqueduct project has been designed and is being monitored by the Western Aqueduct Joint Venture Consultants consisting of Knight Piesold, Naidu Consulting and Royal Haskoning DHV Consultants.

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Enquiry No: 2

KZN regional productivity awards winners

From left: Debbie McCarthy, TLC (Training Leadership Consulting) Winners Emerging Sector, Middle: KC Moonisami Managing Director from Blendrite – Winners Corporate Sector and Ms Dudu Sithole from Duduma Cleaning Service - Winners Co-operative Sector

hree top performing companies in KwaZulu-Natal have taken honours at the Regional Productivity Awards. The trio who walked away with the top spots are Training Leadership Consulting (Emerging Sector), Duduma Cleaning Services (Co – operative Sector) and Blendrite Chemicals (Corporate Sector). Productivity SA Regional Manager in KwaZulu-Natal, Ms Amelia Naidoo, says the awards aim to galvanise companies into greater levels of productivity thereby enabling the

growth and competitiveness of South Africa. Since the inception of the awards in the early seventies, Productivity SA has recognised and awarded more than a 100 different enterprises both in the public and private sectors for their efforts in improving and sustaining productivity. The Annual Regional Productivity Awards will culminate in the National Productivity Awards later this year and the regional awards winners are shortlisted to participate in the Enquiry No: 3 National Awards.

KZN Funding Fair proves its mettle continued from page one division and sharing of risk and also ensures full asset life maintenance and strict performance standards that ensure efficient delivery,” he said. KwaZulu-Natal, as one of the top three provincial economies in the country, is host to some of the most important Strategic Infrastructure Projects in the country. It is the point of origin of the Durban Free State Gauteng freight and industrial corridor facilitated by its proximity to Gauteng. The eve of the Funding fair also saw the official unveiling of the Dube Trade Port by President Jacob Zuma. These projects stimulate devel-

opment which leads to growth in the provinces, towns and cities which in turn requires further investment in bulk infrastructure. The funding seeks to identify and unlock such opportunities. Pottas concluded by noting that infrastructure projects can also help the province develop economic hubs around its towns and cities such as Pietermaritzburg, Richards Bay, and Ladysmith. Hubs can be centered around technology, healthcare and agriculture and agro processing. The important first step is to connect the right funding to the right opportunity, and events like the Funding Fair are key to that process. Enquiry No: 4

P O Box 1322 Wandsbeck 3631 Tel: (031) 266 7511 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 KwaZulu-Natal are welcome. All contributions will be considered for publication.

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Disclaimer: The editor and management of KZN 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

October / November 2014

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KZN Industrial & Business News

International company expands into Cato Ridge

SP Group Africa, a world leading engineering and design company, recently completed the design and construction of a manufacturing plant in Cato Ridge for Indian-based SRF, heralding the first time the manufacturing company has ventured outside Asia. SRF specialises in the manufacture of packaging plastics, engineering plastics, and chemicals. The plant forms part of its global expansion strategy to build the first Bi-Axially Orientated Polypropylene - flexi film - manufacturing and metallisation facility in South Africa that would provide the base to supply targeted food industries across Africa, Europe and America. “Once the business case had been approved and the land had been procured, SRF embarked on selecting a combined Engineering and Architectural service provider. During the process, they contacted various International multidisciplinary firms to provide a proposal for the integrated design services required for this project,” says Peter Steyn, director of Process and Project Management at WSP.

”WSP’s proposal was successful because of our international presence, which shadowed some of SRF’s future expansion plans; our specialist skills and expertise within the food and beverage industry; our sound knowledge of global and local current Good Manufacturing Practice (cGMP); our experience within the South African construction industry as well as our experience with business and strategy in this type of industry.” For Architectural and Quantity Surveying services, WSP embarked on some carefully selected partnerships with small /medium sized local firms that were contracted on a subconsultancy basis. “For a project in which the bulk of the capital expenditure is process and utilities biased, as in this case, it is essential that the project is engineering driven, in order to guarantee the client the optimal manufacturing solution. As such, it was important that the partners we selected to work with on this project shared a common view of project delivery,” adds Steyn. The WSP team visited the SRF plant in Indore, India to gain a clearer understanding

of the scope of the project, as well as some of the technical aspects required. Despite the fact that SRF had very limited knowledge of the local market, WSP was able to work closely with its Indian office to gain insights on the cultural differences. A panoramic view of the factory floor “As the client had built several similar facilities before in India, they had a lot of input to add Despite these challenges, the design took 12 and were extremely hands-on through every months, with construction taking a further 12 phase of the project. The client’s involvement months to complete. and WSP’s knowledge of international best “The socio-economic impact this plant will practice and manufacturing in Africa worked have on not only the region – where Cato well together to result in a facility that is state Ridge has been earmarked to be a drive terof the art in its sector,” states Steyn. minal for development in the KwaZulu-Natal During the design phase, WSP had to be province - but also on up-scaling South Africa’s cognisant of the Indian approach of Vastu manufacturing capabilities, make this a lasting Shastra, consisting of precepts on how the legacy and one that we are proud to have been laws of nature affect human dwellings. This so integrally involved in,” concludes Steyn. resulted in a number of layout designs having Enquiry No: 5 to be adapted to align to this different approach.

Water crisis result of lack of understanding

lame for the growing water crises in South Africa has been shifted from corruption at municipal level, to lack of maintenance planning at water treatment facilities, to copper theft and electricity infrastructure failures, and most recently, to the unexpected hot weather. According to supply chain experts, the long term solution to the ongoing service delivery problems of South Africa should begin by changing the public sector understanding of basic supply chain management principles. “In acting on their mandate to deliver basic services to citizens, state officials tend to focus

on the procurement of goods and services rather narrowly, whereas they should be looking at the supply chain as a whole, from the sources of raw materials to the end-user,” says Colin Seftel (pictured), a former director of SAPICS, the industry body for supply chain professionals in South Africa. Seftel explains that procurement refers to the specific function of purchasing goods and services from a direct supplier, and takes little account of the upstream suppliers and processes that go into the production of goods, maintenance of infrastructure and delivery of services. By contrast, supply chain management looks at the whole chain, which usually begins with the production of raw materials and ends with delivery to consumers.

Supply chain management attempts to balance supply with demand, and so its starting point is the consumer demand. In balancing supply and demand, it includes disciplines such as demand planning, quality management, capacity planning, maintenance planning, as well as increasing and upgrading infrastructure and resources in line with future growth. The supply chain management way of thinking is better understood in the private sector, where companies have to compete for business. Oversupply represents a potential loss to a company, whereas undersupply results in unhappy customers who are likely to take their business elsewhere. In industries with advanced supply chains, such as the automo-

tive industry, companies understand that they exist—and are competitive—only insofar as the supply chain of which they form part is operating optimally. Thus all the companies within a particular supply chain collaborate as closely as possible. This means sharing the vital information flowing from the customer, and then optimising all activities along the supply chain in the light of that information. “Government’s supply chain has somewhat different dynamics, but the principles are not dissimilar,” Seftel maintains. “The current problem however stems from the strong focus on procurement in government supply chains, instead of a focus on delivery.” Enquiry No: 6

October / November 2014

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KZN Industrial & Business News

Eskom’s decline highlights need for alternative energy

skom’s recent request for its customers to reduce energy consumption, even if it means reducing production, together with ordered blackouts, poses a real threat to the growth of corporate South Africa. This is according to Manie de Waal (pictured), Head of Sales at Energy Partners, who says that together with affecting national development, Eskom’s current inability to deliver uninterrupted electricity has a massive impact on companies’ annual earnings. “The full financial effect of load shedding is often hidden as it is ‘revenue not earned’ as opposed to actual financial losses. In 2008 the National Energy Regulator of SA (Nersa) reported that it had cost SA’s economy a staggering R15bn.” De Waal says that there is a direct link between economic growth and an adequate

energy supply which means that corporate South Africa must move collectively towards implementing feasible solutions to ensure continued foreign investment and national growth. “There is already considerable interest and foreign investment into South Africa’s energy efficiency, as proved by the Private Sector Energy Efficiency programme (PSEE) which falls under the National Business Initiative (NBI) umbrella that has R150m worth of foreign funding available for development of energy efficiency awareness and projects.” Alternative energy sources must be utilised strategically to minimise cost during a blackout, says de Waal. “Renewable sources of energy, such as solar and wind, can facilitate processes in the event of a blackout.” However, he says, the nature of renew-

able energy is irregular as it depends heavily on external sources and storage technology is still very expensive in SA. “Typically renewable sources do not form the base-load, but are specified according to the site, which means it hardly ever supplies 100% of power on site. This means that even in energy efficient buildings, a portion of the energy will come from Eskom, which leaves the site exposed in the event of a blackout. It is thus imperative to work with an energy partner that can customise your solution to meet specific needs at the most affordable cost.” He says another popular solution in the

event of a blackout is generators, but these are a costly energy source at approximately R5 per kWh in comparison to R1.10 per kWh from Eskom. “When selecting a generator it is important to use a reputable supplier who will take responsibility for the maintenance of the generator and ensure that the maximum demand for the site will be sufficiently serviced.” Often, the most efficient solution will combine renewable and backup (generator) energy solutions and incorporate these into a business’s existing infrastructure, says de Waal. This methodology minimises the risk of business interruption at the most affordable cost. “In order to reduce reliance on Eskom for energy requirements, business owners should ask a reliable energy efficiency partner to conduct an energy audit to ensure that energy processes and solutions can be implemented for optimal efficiency. This is particularly important for businesses that rely heavily on electricity for key processes such as manufacture, agriculture and mining,” concludes de Waal. Enquiry No: 7

KZN manufacturer wins quality award

psos South Africa recently released the 2014 product quality and customer experience awards winners and amongst the 18 brands from 12 manufacturers that participate, the quality that is synonymous with Toyota South African Motors was evident. Toyota dominated in the light commercial vehicle category with best LCV brand overall (PP100 score of 39), best one-ton single cab brand overall (39), best one-ton double cab brand overall (39) and best local plant manufacturing light commercials (38). “Quality has always been a big aspect in the customer’s decision to purchase

a vehicle. We believe that the nature of the industry has required higher standard overall including quality and customer experience. At the centre of Toyota is the philosophy of Quality, Reliability and Durability. We endeavour to maintain a high standard of quality,” says Calvyn Hamman, Senior Vice President Sales and Marketing. In addition, Toyota also won a silver award in the best volume passenger car brand and a bronze award in the best local plant making passenger cars category scoring 28 in both categories. Toyota also won three gold awards in the eleven sub categories which make up the passenger section including Toyota Auris (Top Hatch), Toyota Avanza (Multi-Purpose Vehicle - MPV), and Toyota FJ Cruiser (Small

Recreational Vehicle - RV). This is the largest study of this kind in South Africa and forms part of Ipsos’ Syndicated Automotive Research. The study currently talks to more than 10 000 vehicle owners each year. The quality survey takes place three months after purchasing a new vehicle to ascertain any problems experienced with the vehicle. The industry average number of problems per 100 vehicles (PP100) has remained around the 40 mark since 2011, which is a huge improvement since 2005 when this measurement indicated a score of over 140 problems per 100 vehicles recorded. Enquiry No: 8

Repositioning milestone

he implementation of Ithala’s group repositioning journey to reclaim its position as the prominent Developmental Finance Institution in KwaZulu-Natal is paying dividends and the organisation recently received a “clean audit”, as determined by the Auditor General South Africa (AGSA), for the financial year 2013/14. The AGSA declares a “clean audit” if the financial statements are free of material misstatements and there are no material findings on both the annual performance report and noncompliance with key legislation. The strategy comprised an initial phase focussing on strengthening the institutional, financial and governance foundation that is essential to support business growth. This is a five year programme, with the first two years being about “stopping the bleeding”. The culmination was the target set for 2013/14, to achieve a “clean audit”. Notwithstanding Ithala achieving an unqualified audit opin-

ion over the past five years certain material findings prevented Ithala from achieving a clean audit. Whilst this milestone has been achieved, the challenge is for Ithala not to regress and to continue to now maintain this status. With continuously changing standards and increasing reporting Losh Peruma, Audit Manager at Auditor and legislative requirements in the public sector, the workload General South Africa, hands over the clean audit report to Ithala CEO, Yvonne Zwane to maintain this status remains substantial. “Our repositioning strategy has enabled Ithala to get its house support and guidance of our MEC, in order and re-assert its develop- Michael Mabuyakhulu in helping us ment role. Achieving a “clean audit” achieve this milestone and we extend indicates that our drive to promote a special thanks to AGSA for their good corporate governance, coupled patience, diligence and strong partwith the implementation of stringent nering approach to our work together. policies, is paying dividends. It is now Last but not least, we must acknowlabout implementing the many initia- edge the significant role played by tives that will provide the impetus Team Ithala comprising our Board, for change,” said Ithala Group Chief Executives, Management and our Executive, Yvonne Zwane. employees,” added Zwane Enquiry No: 9 “Furthermore, we recognise the

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October / November 2014

KZN Industrial & Business News

Company profile: engen lubricants

Engen Lubricants.

Reliable lubricants for the toughest environments. Engen Petroleum is a subsidiary of PETRONAS, the national oil corporation of Malaysia, and a leading provider of lubricants to the South African market. Engen offers a range of high performance lubricants that are purpose-suited to a spectrum of industries. We supply both the automotive and industrial sectors and provide products for petrol and diesel engines, gearboxes, hydraulics, turbines, compressors, machine tools and a variety of other applications from both mineral and synthetic base oil stocks. Engen represents PETRONAS Lubricants International’s interests in Africa PETRONAS Lubricants International (PLI) is a wholly-owned subsidiary of PETRONAS. Fully established in 2008, PLI is the union of two respectable lubricant companies – FL Selenia and PETRONAS’ own Lubricant Unit. As a result, this has sparked off a new organisation that is structured and focused on offering the best lubricants and functional fluids to the world. The binding and driving factor behind PLI is its commitment to its role as a Fluid Technology Solutions™ company for today and tomorrow. Engen Petroleum, as a subsidiary of PETRONAS, also represents PLI in Sub Saharan Africa and the Indian Ocean Islands and benefits from access to this global player’s advanced technology. PLI is supported by seven blending and filling plants worldwide; Contagem in Brazil, Turin and Naples in Italy, Durban in South Africa, Barcelona in Spain, Hemiksem in Belgium and Melaka in Malaysia. Designed to produce the same quality fluids as those produced by scientists in the lab, these plants are equipped with automatic control systems. Apart from achieving accuracy and consistency, it also eliminates the possibility of errors. PLI’s filling facilities on the other hand, employ a mix of automatic as well as adjustable lines. This is to ensure that PLI is flexible in filling its fluids into various package requirements to satisfy a wide array of users. All PLI plants are officially certified ISO9001 for quality management, and ISO14001 for environmental management. As an innovative organisation dealing with the complex engineering of fluids, PLI is backed up by two world-class R&D Centres covering the West and the East; Turin, Italy and Bangi, Malaysia. The latter is also the hub for PETRONAS’ scientific petroleum research activities. Both facilities are fully equipped with the latest instrumentation to perform sophisticated fluid development tests, such as liquid and gas chromatography, infrared radiation, plasma magnetic field, thermal analysis, tribological tests, and more. To cater to automotive needs, multiple engine test cells are available to perform all kinds of fluid development works. These include bench and dynamometers with intelligent automatic drivers to provide as real as possible inputs. These two centres are familiar playgrounds to many leading OEMs and corporate users in their search for fluids that match the values they are seeking. Progressively, these centres are consistently updated to keep up with the ever-changing world of engineering. Whilst all design and refinement work begins in the chemical development lab, PLI’s fluid development process passes through a real-world simulation lab prior to actual usage. Then what is termed the progressive lab, where the used fluid is periodically tested and modified accordingly to match the changing conditions of the mechanical parts, comes into the picture. PETRONAS is an active player in motor racing, be it at the local, regional or world’s highest level. Motorsports, particularly Formula One, is a sport that is built on technology. Every little engineering input is translated into the resulting improvement of lap times, and fluid is no exception. PLI designs, develops and supplies customised fluids for the MERCEDES AMG PETRONAS Team’s application in Formula One. In doing that, PETRONAS becomes a functional partner to the Team, where its input is translated into actual lap time. It is a challenge that PLI genuinely takes pleasure in as the method, discipline, culture and pressure of working in the Formula One environment helps enrich itself as an organisation. The ultimate performance synthetic engine oil Bred on the track for optimum performance on the road. The PETRONAS Syntium range is the result of advanced R&D carried out by PLI as the official technology partner to the Mercedes AMG PETRONAS Formula One Team. It meets the most stringent industry standards and is designed to take on the most challenging terrains and driving conditions. The PETRONAS Syntium range of automotive lubricants is available in Southern Africa through Engen Petroleum. Sole distributor of Air1 in Sub Saharan Africa In its efforts to be a one stop shop for fluid requirements, Engen has recently introduced Air1, the world’s leading brand of AdBlue, to its product offering. AdBlue is the registered trademark for Aqueous Urea Solution 32.5% that is used with the Selective Catalytic Reduction system (SCR) to reduce emissions of oxides of nitrogen from the exhaust of diesel vehicles. By selecting Air1, you ensure that wherever you are located, your Engen Truck Stop will be able to supply you with a reliable source of quality AdBlue. Advanced industrial gear oils Engen is also bringing high performance under extreme conditions to industrial gearboxes with the launch of the Gengear XEP series. Modern gearboxes are smaller and designed with higher power density, smaller sumps and higher load capacity, putting enormous pressure on the lubricant. Modern gear oils must be formulated with higher-quality components, designed to excel under these challenging conditions. The Engen Gengear XEP range has been developed using the latest technology so that it meets a range of complex demands such as protection against micro-pitting wear, resistance to foaming and compatibility with seal elastomers. Gengear XEP series is approved by major manufacturer Siemens MD. Distributing reliable lubricants throughout Africa Engen promotes economy and security of supply across our vast international network and supply chain. In South Africa, primary distribution centres are present in all major cities, and a number of secondary depots are situated in outlying areas. Depots and storage facilities can also be found throughout our network in Sub Saharan Africa and the Indian Ocean Islands. Products are dispensed to both the countries where Engen has assets and operations on the ground, as well as through distributors in other countries where we have no physical presence. Distribution and technology combine to offer a fully-mechanised, truly efficient system designed to meet and exceed customer needs and demands. With Engen Lubricants, you get over a century of experience and world-class support, as well as a comprehensive range of lubricants that ensures the maximum efficiency and lifespan of your machinery. You also get the technical expertise and knowhow of a leading global supplier of lubricants. In other words, you get a smooth, trouble-free operation.

ENGEN – With us you are Number One. Customer Service Centre: 08600 36436 | Email: 1call@engenoil.com | Website: www.engenoil.com

October / November 2014

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KZN Industrial & Business News

Key industries in KZN to have access to latest efficiency electric motors T he sugar and other key industries in KwaZulu-Natal will have access to the latest efficiency electric motors after the Zest WEG Group announced it will introduce IE3 compliant electric motors as standard in place of the current IE2 range from January 2015. WEG’s ongoing commitment to R&D has ensured its international reputation of producing top quality energy efficient electric motors,” Taylor Milan, Zest WEG Group, Durban branch manager, says. Based in the River Horse Valley Business Estate in Durban North, Zest WEG Group KZN is well positioned to consolidate the group’s presence in key markets in the province such as the VSDs are becoming increasingly important in terms of energy savings and machine optimisation, says Glen Ward, VSD Manager KZN – Drives & Automation

sugar, water, paper and petrochemical industries. “Rising electricity costs have placed the spotlight firmly on energy efficiency and process optimisation,” Milan says. The introduction of IE3 compliant electric motors will be welcomed by the province’s key industrial markets, Milan predicts. “A key aspect is that this change will be introduced at no additional cost to our customers, thereby reducing the total cost of ownership.” Improving the energy efficiency of electric motors effectively reduces the real cost of ownership over the lifespan. Apart from standardising the premium efficiency motor range as IE3, the Zest WEG Group has also launched the new W50 and W60 range. The W50 electric motor is available in a voltage range from 380V to 6 600V and rated output of 75 kW up to 1 120 kW. The W60 electric motor is available in

a voltage range of 2 300 V to 10 000 V, two and four pole and a power output of up to 2 500 kW. The new model has a compact and robust frame with the length and weight having been reduced by up to 18% in certain instances. It also offers reduced noise levels, increased cooling, optimum efficiencies, insulated NDE end shield and a state of the art air deflector on the DE end shield ensuring lower bearing temperature. The motors are based on a modular concept so that the fitment of accessories such as forced ventilation kits and encoders can simply be added on rather than necessitating a total design change. “The applications where these electric motors are installed require a range of mounting configurations. This versatile design can accommodate a full range of mounting configurations, in addition to the add-on versatility offered by the modular Enquiry No: 10 concept,” Milan says.

Entrepreneurs growth centre launched

INDUSTRIES The CDAA strongly encourages all eligible companies to consider membership in order to create business opportunities and grow the copper industry.

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to promoting and expanding the use of copper and copper alloys throughout Africa and has successfully represented the local copper industry in southern Africa for more than 50 years. With the purpose of growing the industry on a sustained basis and realising an increase in the use of copper in Africa, the CDAA is expanding its membership base to include the full spectrum of companies in the copper industry, from primary through to downstream companies and service organisations.

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aspects of the business, such as bookkeeping, administration or legal issues.” “With the launch of the Entrepreneurs Growth Centre, Business Partners Limited intends to bridge this gap by bringing the information needed to run a successful business to the entrepreneur, addressing the challenges that entrepreneurs face, and ultimately promote and develop entrepreneurship in South Africa,” says Botes. Although the Entrepreneurs Growth Centre is based in Johannesburg, the services are available nationally via email and LinkedIn, as well as through an expert call centre. By contacting the centre, entrepreneurs will have access to trained business mentors who are equipped to provide educated information and advice. The Entrepreneurs Growth Centre will provide advice on all aspects of running a business, which include day-to-day running requirements, tendering processes, employee and risk management, as well as information around the regulatory environment in a specific sector. Enquiry No: 11

Foundation improvement toolkit for schools n innovative toolkit developed A by the General Motors South Africa (GMSA) Foundation for

Membership includes the following benefits:

Statistics Market development through initiatives

usiness Partners Limited, a specialist risk finance company for formal small and medium enterprises (SMEs), has officially launched its Entrepreneurs Growth Centre, a facility that will provide free support and service assistance to local entrepreneurs. The announcement of the Business Partners Entrepreneurs Growth Centre follows the recent unveiling of the company’s entrepreneurship campaign – the square peg movement – which aims to champion entrepreneurship as an answer to South Africa’s economic growth and job creation challenges. According to Christo Botes (pictured), Executive Director of Business Partners Limited, when entrepreneurs are asked to identify the problems they face, access to finance is commonly cited, and then, stated as equally important, is access to support services. “While finance remains a driving factor for starting a business, nonfinancial support such as access to information, business expertise and resources are listed as key needs for entrepreneurs to keep their businesses running, turning profits and creating jobs.” “Many entrepreneurs have industry-specific skills, but don’t necessarily have the training or experience to manage other

schools to develop and manage their own improvement plans has embarked on a countrywide rollout to the rural Eastern Cape, KwaZulu-Natal and Western Cape, in partnership with the Department of Basic Education (DBE). The web-based Whole School Self-Evaluation (WSSE) toolkit, developed by the GMSA Foundation and successfully implemented in a number of Nelson Mandela Bay schools, was recently rolled-out to 113 schools in Lusikisiki in the rural Eastern Cape, and piloted in 36 schools in 12 districts in KwaZulu-Natal. “The beauty of this toolkit is that it covers all the areas of the operation of a school, and it includes all stakeholders. Together, they focus on the whole school development so that they can change the whole school.”

“It enables schools to identify and prioritise their needs, and to monitor and evaluate implementation in partnership with the national Department of Basic Education,” said GMSA Foundation project manager Delia Freemantle. The WSSE instrument enables schools to measure their own performance and resources in nine key areas, namely the quality of teaching and learning, and educator development; provision of curriculum and resources; learner achievement; basic functionality; leadership, management, and communication; governance and relationships; school safety, security & discipline; school infrastructure and parent and stakeholder involvement. Training in KwaZulu-Natal included 45 Education Department officials and management, teacher and parent representatives of 36 schools. Enquiry No: 12

October / November 2014

KZN Industrial & Business News

MATERIALS HANDLING, BULK HANDLING & LOGISTICS

Unveiling the world’s largest telehandler

anitou Southern Africa recently launched the world’s largest telehandler, the MHT-X 14350, as well as three new flameproof mining machines, a scaler, roof bolter and tow tractor. With a nominal lift capacity of 35 tons on its 14-metre duplex turret, the Manitou MHT-X 14350 delivers an unprecedented level of mobile handling capacity to surface mining, heavy and general logistics industries. Designed with a renewed empha-

sis on size for increased productivity in the increasingly heavy-load handling requirements characterising modern heavy industrial applications, the MHT-X 14350 is a versatile, reliable and robust rough terrain, all-purpose vehicle that delivers unparalleled handling capabilities with increased safety and ergonomic operator comfort. The model features advanced usability improvements with a 7.2 litre, 240 kW Mercedes-Benz engine deliv-

ering a massive 1 300 Nm to cater for the mining and heavy-industrial sectors, with enhanced handling ability of large conveyor belt reels, tyre assemblies, wheel motors, granite blocks, and so forth. In addition to advancing the lift capacities of mobile material handling equipment, Manitou have also launched three new flameproof mining machines to its expansive range of mining equipment: the Manitou Scaler, RoofBolter and ManiTrax Tow Tractor. The Manitou Scaler enables operators to scale hard and soft rock from secure areas on its seven metre, 180° rotational turret, either from within its fully-enclosed cab, or from up to 20 metres away via remote control for maximum safety. The scaler can be fitted with several attachment variations itself, and has secondary functions such as pipe and cylinder fitment, mesh erection and the destruction of large rocks. The Manitou RoofBolter is an automated drill and bolt rig that offers manoeuvrability and performance in confined soft and hard rock hanging walls as low as 1.8 metres.

The RoofBolter, a permanent fixture to the Manitou MT-X 742 Telescopic Handler, consists of a single six-bolt rotating carousel head to enable drilling, automatic epoxy injection and bolting functions in a single procedure to offer massive cost-savings for customers. The ManiTrax Tow Tractor, used

for hauling, towing and transporting purposes, is designed with full four-wheel and crab steering functionality for maximum manoeuvrability in confined underground spaces. Positioning operators forward in the carriage, the ManiTrax offers enhanced visibility, and thus safety. Enquiry No: 13

Charge bay management system

night Power Solutions (Pty) Ltd is a Durban based business that services, supplies and maintains a wide range of industrial batteries and chargers for electric material handling equipment such as forklifts, reach trucks, pallet trucks, tow motors and scrubber and sweeper machines. The company also supports material handling equipment manufacturers such as Nissan, Jungheinrich, Crown, Doosan, BT, Clark, Toyota and many more. In addition the company also offers battery charge bay management and battery and charger maintenance and service agreements in addition to its service and product offering. Knight Power Solutions supplies internationally recognised brands and has partnered with a national group of companies with over 30 years of experience in the industrial battery and charger market. The fact that these partners have branches throughout South Africa based particularly in Johannesburg, Cape Town, Port Elizabeth, East London and Durban, allows “KPS” to service clientele both locally and nationally at any time of the day or night. New on offering from the company is the latest and most competitively priced Charge Bay Management System in the world. This system was developed in Sweden and is available worldwide as the “MP Access” system. The features that distinguish this system from its competitors are the fact that the chargers come with a built in management system, offer up to 30% elec-

tricity consumption savings and have an efficiency rate of 94%. In addition the programming offers a multi voltage charger, which ensures never having to replace the charger when replacing the machine. A Best Battery Choice feature (BBC) helps the operator to change to the best battery in a fleet, and 30 pre-programmed charging curves offer optimal charging at all times. A number of other unique benefits also make this the system and service provider of choice for a number of local clients. These include Kintetsu World Express in Prospection, BME Packaging in Umbogintwini and Bidvest Food Services in Riverhorse Valley. Nationally it has also proved to be invaluable to companies like Shoprite DC in Port Elizabeth, Reckitt Benckiser SA in Johannesburg and the PepsiCo Group countrywide. The company supply Traction batteries and cells manufactured in Greece by the World’s 2nd Largest Manufacturer to further complement their superior charger product line. Enquiry No: 14

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October / November 2014

materials handling, bulk handling & logistics

KZN Industrial & Business News

Information in the logistics process

argo transport in South Africa is an industry faced with a number of challenges. Companies in this sector have one overriding objective – move their cargo as fast as possible to where it is required. However, infrastructure problems make this a difficult task, and often cargo transport companies are simply unable to move the cargo as fast as they are receiving it, causing backlogs, inefficiencies and a host of other challenges. Telematics solutions have become increasingly common as a way of mitigating this challenge. However these solutions often differ from supplier to supplier, and thus are limited by an inability to integrate. In order to optimise and gain maximum control over logistics processes, access to integrat-

ed real-time information is critical – which requires a platform to bring disparate telematics together, says Michael Frans (pictured), Business Development Manager-Automotive, T-Systems in South Africa. The cargo transport sector is one that deals in precision. When containers arrive at the various ports in South Africa, they need to be moved quickly to their destinations. The cargo ships themselves have schedules to meet, and the trucking companies need to deliver goods to customers within a certain time frame, particularly if the goods are perishable. However, moving cargo from the ports, through cities, across provinces and to different areas

relies on limited road and rail infrastructure, which often causes bottlenecks. If there are delays at the harbour, or accidents along the roads, or if the trains are not running on schedule, cargo is delayed. Truckers may have to wait outside ports, or on roads, potentially causing traffic congestion. In addition, they are being paid for their time but are not productive due to delays. These are but a few examples of the many challenges these companies face. Having the necessary information in real time about every aspect of the cargo value chain can assist logistics companies to gain greater control and optimise their processes, helping them to deal with

these challenges more effectively. Telematics solutions have become increasingly common in the transport and logistics sector as a way of providing this much-needed information. However, when trucks and trailers from different suppliers with different telematics systems are combined into a single convoy, valuable information may be lost, as manual reconciliation between the different systems is required. Often, different systems from various suppliers cannot work seamlessly together. In addition, individual systems do not provide any benefit to any of the stakeholders outside of the owners of that system. In order to effectively tackle the challenges in the cargo logistics sector, siloes need to be broken down using an integrated, cloud-based, vendor-neutral aggregation platform

to bring together information from various telematics systems in realtime. A standardised interface, with dynamic central data visualisation that is independent of vehicle manufacturer, telematics provider or stakeholder, will create visibility throughout the value chain. This enables all stakeholders to obtain the information they need to monitor and track cargo throughout the value chain, in real-time. There are endless possibilities for the data stored within telematics solutions – it is all about how this data is managed, and the ability to break down siloes to deliver real-time information to stakeholders when and where they need it. This in turn helps to close the gap between transport and logistics providers and their customers. Enquiry No: 15

Tallest super boom in Africa

oscor Hi-Reach recently introduced the Genie SX-180, the tallest self-propelled Super Boom yet in Africa, with a remarkable working height of 57m. “As the official distributor of the well-known Genie range of equipment in Southern Africa, we are very pleased to bring this exciting new lifting solution to the market,” says George Landsberg CEO of Goscor Hi-Reach, part of the Imperial Group. “The Genie SX-180 is also immediately available to the Southern African market as a rental option from Goscor Access Rental,” according to Managing Director, Dean Jones. The SX-180 next generation telescopic boom lift has been specially engineered to meet the highest workat-height installation, erection and maintenance requirements across a broad market spectrum, from general construction and chemical industries to utilities, airports, harbours and refineries. The design of the Genie Super Boom is centred on extensive customer feedback to meet the demand for rugged reliability, fast manoeuvrability, and easy maintenance and transport. With a staggering vertical reach of 57m and a 24.4m horizontal reach, the boom lift goes almost 10m higher than any previous self-propelled boom lift. “Furthermore, it is fully extendable or retractable in just five minutes,” adds Landsberg.

The impressively tall, tough 26,000kg machine is powered by a choice of new-generation Tier IIIB Perkins or Deutz 74-hp engines and can be driven at full height. Landsberg points out that travel speeds vary based on boom position and range. A 225 litre fuel tank, for longer running time and a 7.5 KW generator are standard on the machine. The Genie’s patented extendable and retractable X-Chassis is specially engineered to provide stability on the job and to facilitate transport. The machine’s axles are adaptable to specific heavy jobsite requirements and

Enquiry No: 16

Keeping the wheels of progress turning

FROM THE GIANT TO THE NIFTY From the biggest 2000 ton Goliath shipyard crane in the world to compact Manual Chain hoists, Konecranes has the lifting solution for you

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can be extended from 2.49 m up to 5 m; very heavy gauge steel box-section frames provide extremely stable and safe foundations when the axles are extended. Once retracted, the axles are also easily stored within the undercarriage for easy transport. As the only machine of its kind to combine such an impressive platform height with balanced machine weight and compact stored dimensions, the SX-180 can be transported virtually anywhere in the world without over-width or over-weight permits.

ir Products South Africa, has acquired a fleet of new tankers, and plans to invest in further capacity in the coming year. These investments were seen as vital in order to service a growing customer base, as well as an increase in demand from existing customers, according to Hein van Tonder, Supply Chain and Bulk Distribution Manager at Air Products South Africa. “The fact that our existing fleet was ready for an upgrade was another factor which led to this decision. Also, because of the increase in market demand, we knew the time was right to invest in a new fleet, specifically with a higher payload,” van Tonder says. The tankers, which were imported into the country have increased payload for liquid oxygen and liquid nitrogen. The company can now deliver more tons to customers in KwaZulu-Natal and the Western Cape. Customers of bulk product include the petrochemical, mining and metals processing industries. Air Products prides itself on supply chain thought leadership and operational efficiencies, and believes that an effective and flexible supply chain is critical in maintaining a leading position in the gas industry. “While being a producer of gas and gas products has always been our primary function, certain market drivers have forced us to change our focus to fine-tuning our supply and servicing capabilities. We see ourselves therefore not as a gas company, but a supply chain company,” notes Seelan Gounden, General Manager of Supply Chain Gas at Enquiry No: 18 Air Products.

October / November 2014

KZNâ&#x20AC;&#x2C6;Industrial & Business News

materials handling, bulk handling & logistics

October / November 2014

KZN Industrial & Business News

Belt rip detection system launched

ecker Mining South Africa has launched its new BRS-2 belt rip detection system, designed to increase the productivity of conveyor belts by detecting belt rips as soon as they occur. “This belt rip detection system, which is based on the highly efficient design of the original BRS-1 system, is used to detect longitudinal rips on steel cable and fibre conveyor belts,” says Johann Smit, chief sales officer, Becker Mining South Africa. “The BRS-2 uses real time loop diagnostics to continuously monitor the status of the belt and, in the event of a rip, stops the belt drives, which reduces any further damage and minimises downtime.” symostorage_150x100_advert.pdf To monitor the status of a belt,

inductive loops are embedded in the belt. Once installed, the BRS-2 system carries out an identification run and the processor of the belt rip detection system unit (BRS/ CU) stores the necessary data. Parameters include the succession of loops in the belt, belt speed and start up time of conveyors. Stored values are protected against power loss and can be entered or changed when necessary. When the belt is in operation, these inductive loops pass over the transmitter and receiver, which are 1 2014/10/22 3:29 each PM positioned opposite other on

either side of the belt. An electromagnetic signal is transmitted via the inductance loop from the transmitter into the receiver. Because this system has recorded the distance

between successive loops and belt velocity, it can automatically calculate the time intervals between each loop. The belt rip sensor that is embedded in the belt operates like a bridge between transmitter and receiver of the belt rip scanner sensor interface (BRS/ SI). If a belt is ripped, the BRS/SI cannot measure any analogue values from the destroyed loop. Apart from the detection of belt rips, this system is designed for monitoring belt speed, the detection

of belt slip and also for belt sequence control. Access and monitoring of the system is simple, either locally with its 12” TFT screen, five shortcut buttons, a mouse pad and virtual keypad, or remotely via TCP/IP or other bus standards. Other features include real time graphics, a forward and reverse capability, local and remote password protection and a record of the last 10 000 system changes. This device, which can withstand operation in arduous conditions, has a robust stainless steel housing, with an IP65 index protection rating to guard against the ingress of dust and water. Enquiry No: 19

Compact in size, big on delivery

esigned to perform in demanding civil and building applications, the Cat mini excavator range has undergone major advances in terms of overall functionality since Caterpillar’s first entry into this product segment back in 1998. Since then there have been successive model series changes and a steadily expanding global machine population. In addition to the contracting, industrial and municipal markets, Cat mini excavators are also popular choices for plant hire fleets, especially given their road-legal towing weight and overall versatility. A popular mid-range choice within Caterpillar’s mini line-up for the southern African market is the 5,5 tons operating weight Cat 305.5E model, which is supplied locally in compact radius (CR) configuration (the radius of the upper body staying within 140 mm of the undercarriage). “Compact radius models are ideally suited to working in restricted spaces, such as inside buildings and in urban areas for applications that include demolition, road rehabilitation works, and trenching and pipe laying for telecommunications and underground water reticulation services,” explains Barloworld Equipment product marketing manager, Desigen Naicker. The Cat 305.5E CR is equipped with a Cat C2.4 engine with a rated net power of 32,9 kW at 2 400 rpm (ISO 9249) and has an operating weight of approximately 5 415 kg when fitted with a FOPS cab, which

is standard for this market. On the go, automatic two-speed travel simplifies operations. All E-Series models feature high digging forces, fast cycle times and excellent stability, with operation via pilot controls. An advanced load sensing system provides responsive performance, whilst boom and cylinders incorporate end damping to reduce shock loading and bucket spillage. Depending on whether the machine is fitted with a standard or long stick, the Cat 305.5E CR can excavate down to a depth of approximately 2 330 mm and 2 730 mm, respectively. Digging forces are 28,9 kN for standard and 24,8 kN for long stick applications. Fitted with a wide range of work tools, such as vibratory trench compactors, thumbs for pipe handling, augers, metal cutting shears and Cat hammers, Caterpillar’s mini excava-

tors transform into high production multi-purpose machines, with the option of specifying either a mechanical or hydraulic quick coupler system, the latter enabling rapid tool changeover. E-Series machines include both a single direction auxiliary circuit for use with a hammer, and a two-way auxiliary hydraulic circuit for bi-directional work tools such as augers or angling buckets. A wide range of bucket choices are available, extending from general purpose (GP) to landscaping. A distinctive feature across the board is their over 200 degrees of rotation. This ensures good spoil retention at height, such as during truck loading, plus easier flat back trenching ability. A key feature on the Cat 305.5E CR is the standard COMPASS (or Complete Operation, Maintenance, Performance and Security System) digital control panel, which provides security, performance and economy features. COMPASS’s anti-theft device uses a five digit alphanumeric password that is required to start the machine (when the security system is enabled). Then there’s the adjustable work tool auxiliary flow control, which provides simple adjustability of the hydraulic flow going down the boom and stick to the work tool. This function is particularly advantageous when using a tilting bucket/coupler or thumb on the end of the stick where fine control and precise movement are required. Enquiry No: 20

Truck of the Year 2015

he Renault Trucks T was recently voted International Truck of the Year 2015 by the International Truck of the Year jury during the 65th edition of the IAA Commercial Vehicle show in Hannover. The jury, made up of 25 journalists specialised in commercial vehicles representing 25 international magazines, judged that the Renault Trucks T is the vehicle that has made the largest contribution to road haulage this year. The International Truck of the Year jury awarded the title to the Renault Trucks T on the basis of several criteria: technological innovations, comfort, safety, on-road performance, fuel savings, the vehicle’s environmental footprint and total cost of ownership (TCO). The jury highlighted the Renault Trucks T’s qualities, making particular mention of its state-of-the-art aerodynamic solutions as well as the comfort provided for drivers both when at the wheel and when resting. “The Renault Trucks T combines the qualities of the brand’s previous flagship models with the latest technological innovations in the world of commercial vehicles,” summed up Gianenrico Griffini, the Truck of the Year Enquiry No: 21 (ITOY) Jury President.

October / November 2014

KZN Industrial & Business News

materials handling, bulk handling & logistics

South Africa leads the way by Kevin O’Marah Chief Content Officer SCM World

’ve been pitching Africa as a supply chain growth imperative for a while now. Our recent and bullish Africa report has had some pretty good reviews, making me confident that things are ready to happen. But one caveat keeps surfacing: the talent gap. What to do about finding, developing and managing people who are savvy about local conditions, but also sophisticated enough to navigate the waters at global headquarters? The talent problem in emerging markets is certainly not unique to Africa. We have consumer goods companies probing this question as it relates to entering China, hi-tech companies facing the issue in Latin America, and industrials wrestling with it in India. So much opportunity, but so few qualified people, and unfortunately expats don’t solve the problem since their skills mix is wrong and most are short-timers anyway.

Here is one idea that may help – at least in Africa. Recently I spent two full days moderating a CEO roundtable with leaders from eight big South African companies. The event was noteworthy because it comprised top bosses drilling into how supply chain affects business value. It reached deeper into the business agenda of this group of leaders than anything I’ve seen in the US or Europe. Had this meeting been assembled by the World Economic Forum and held at Davos, I’d have been impressed, but not surprised. Instead it was arranged by SAPICS, the South African premier channel partner of APICS – a talent development organisation with headquarters in Chicago, USA, and a somewhat less-than-glamorous image. SAPICS is empowered to experiment with new ways of bringing business and supply chain together. The influence of these general managers on the SAPICS’ content and engagement strategies is direct as the education agenda is set by business leaders more than by consultants.

Talent development through networking SAPICS hosts a conference every year in

South Africa that draws hundreds of young, ambitious supply chain practitioners from all over the continent. I attended its 30th anniversary event a few years back and left with first-hand accounts of supply chains working in countries from Nigeria and Kenya to the Democratic Republic of the Congo and Zimbabwe. Hundreds of working supply chain professionals soaked up the education, handed out business cards and tried to get an edge in their careers. The vibe was less like emerging markets and more like Silicon Valley, unlike emerging markets events I’ve been part of in New York or London, where the audience was more worried about looking good than about learning.

Emerging markets talent gap not unbridgeable The big takeaway is that talent in emerging markets – in this case, Africa – need not be something supply chain leaders have to face alone. SAPICS is a well-established association with events, members and affiliates all over the continent. It is young, but not green, and open to business input. It also has deep institutional support from APICS Supply Chain Enquiry No: 22 Council.

Integrated business planning

ompanies that do Integrated Business Planning (IBP) well are more efficient, more effective, and make more money than those who don’t, however at the cornerstone of successful IBP are the skills and capabilities within the organisation, and an appreciation that IBP is a business process. “The IBP process only works if there is appreciation of the importance of understanding demand and supply, and finding joint solutions to support achievement of the business objectives,” says Alastair Gore, associate consultant at Aperio, a business consulting company focused on accelerating growth of FMCG brands in South Africa and Sub-Saharan Africa. “From an education perspective we have not developed the capabilities of supply chain students in terms of the level of change that has happened in the industry. A change to curriculum at university and college level is needed

to accommodate what business is facing today to ensure alignment,” says Gore. There are huge gaps in skills and capability, with a lot of specialists in the industry but little broad based business expertise. “There is far too much silo thinking within companies and in order to drive internal collaboration within businesses which is a key component of IBP, people need to understand the impact of their decisions and actions,” he says. Every person in the supply chain needs to understand the impact of what they do. This means broadening the skills of people to understand cause and effect; the impact of the decisions they take on other areas of the business. “95% of business issues begin with a lack of clarity of demand, and supply ends up chasing its tail,” says Gore. “People working in the supply chain don’t always recognise that supply

chain is a business issue, not a functional one.” The impacts of not working together are clearly felt by the business in poor service levels, poor inventory control, and the ensuing financial loss. “We have forgotten the basics and are looking for the silver bullets,” he says. “It’s about driving central collaboration within businesses to ensure they are aligned and doing the right things internally.” “This means defining the customer strategy in collaboration with the customer, and ensuring that the strategy can be executed within the business. Then the execution team must provide operational support to execute the strategy – in this way both demand and supply will be covered. But everyone needs to be involved to understand the business strategy and what needs to be achieved. Enquiry No: 23

It took almost a month on the road and over two years of planning to transport three massive transformers from Richards Bay harbour to the Cahora Bassa Hydroelectric Generation Station in Mozambique. Each of the 149 ton units was loaded onto a separate fourteen axel, 112-wheel flatbed trailer for the journey made at ‘walking speed’ from Richards Bay through South Africa, into Zimbabwe and then on to their final destination in northern Mozambique. “It has taken two and a half years of planning,” says Chris Mulder, Project Manager for Turners Shipping who were responsible for the logistics in partnership with their German agent BDP Logistics for bringing the transformers and the additional 61 cases of accessories which required the use of 11 additional vehicles to their final destination.

Enquiry No: 24

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materials handling, bulk handling & logistics

October / November 2014

KZN Industrial & Business News

Cutting cold storage costs

PC Storage Solutions SA recently maximised the storage capacity and reduced notoriously high cold storage costs for a vegetable company, with its Movirack mobile racking solution. Just Veggies is responsible for storing vegetables from various farms, and is fast becoming South Africa’s largest producer and processor of organic vegetables to the local and international market. Cold storage by nature is very expensive. It is not only costly to operate constant airconditioning, but the actual building of the freezer is complex, due to the special flooring, walling and overall insulation that is required. It was therefore important for APC’s consulting engineers to design a system that would allow the most vegetables to be stored in the least amount of space possible. After careful design-engineering and plan-

ning, APC provided its Mecalux Movirack mobile racking system for the client’s new storage freezer that requires a constant temperature of -25°C. With Movirack , the mobile racking units are installed over guided mobile bases that slide laterally, opening via remote or wall-mounted control only when access is required, eliminating the need for multiple aisles while allowing easy access to all pallets at all times. Movirack is ideal for cutting cold storage costs. With its mobile construction, the company was able maximise the storage capacity by about 50% of the total area because there is no wasted aisle space. The installation consists of nine rows (two static and seven mobile) at 7.5 m high, and with Movirack’s innovative mobile bases, only one access aisle, 4.8 metres wide, is required. This allows the client to store more than 1 000

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pallets in the current space in phase one, equalling to two pallets per square metre. “The challenge we faced in this project was that our team had to install the system in -25°C temperatures because the fridge had to be turned on three weeks before our completion date in order to reach its optimal temperature. This was done so that as soon as the installation was complete, client could start storing stock,” says Shawn Gray, Senior Consultant, APC Storage Solutions SA. “To overcome this, we had various teams each working in 30 minute intervals, due to the -25°C temperature

Meshcape™ Screen Media is an ISO accredited Engineered Consumable Product (ECP) supplier to the Quarry, Industrial and Mining industries throughout Africa. Contact us on: Tel: +27 (0)10 210 5000 • Fax: +27 (0)11 452 2545 E-mail: sales@ludowicimeshcape.co.za • www.flsmidth.com

Enquiry No: 25

More cranes for Husab

ondra has completed one of the crane industry’s biggest manufacturing contracts for the year so far, and have announced an order for a further four cranes from the same customer, AMEC Minproc. The order was received in the same week that Condra despatched a 24‑metre span 50/50-ton maintenance crane with two 15-ton auxiliary hoists, the final machine in AMEC Minproc’s initial order for seven. The eleven cranes have a combined value well in excess of US$2-million, and are all for installation in Swakop Uranium’s Husab mine in Namibia. The Husab project is an openpit mine under development near Swakopmund on the west coast. The high grade, granite-hosted uranium deposit at this mine is Namibia’s largest, and the third-largest uraniumonly deposit in the world. A number of Swakop Uranium’s Condra cranes have unusually large spans, necessitated by the very large size of the mining machinery that they will be used to maintain.

The 24-metre span of the 50/50-ton machine just completed is itself larger than that of the average maintenance crane, but Condra earlier this year manufactured two 40-ton cranes with spans of 30 metres for this mine, and two of the four machines in AMEC Minproc’s latest order are 20-ton units with spans of 22 metres. The remaining six cranes in the clutch of eleven have spans of 20 metres and under. All cranes feature case-hardened gears, live-axle direct drives, squirrelcage motors and adapted V-belt technology, all of which increase machine reliability and lower the

overall lifetime cost. Condra is currently expanding the range of its hoists designed around V-belt technology drives because of their very low maintenance requirements. V-belt drives need no greasing or cleaning. A company spokesman explained that performance delivered to the hoists by V-belt drives is considerably superior to any alternative in tough operational environments where routine maintenance is likely to be overlooked. On the 50/50-ton crane just completed for Husab, Condra installed controls that include a selector switch connected to the main hoist drives, allowing synchronised movement of the two 50-ton hoists to lift a load of 100 tons, or allowing independent operation of each hoist to manipulate a load of 50 tons. Delivery of this machine to Husab took place by road over the first two weeks of September. Enquiry No: 26

Materials handling M goes mobile

A Tradition of Quality FLSmidth is your One Source for crushing, grinding, classifying, thickening, clarifying, slurry handling, flotation, underground mining, pyroprocessing, material handling, automation, engineering, screens, centrifuges and complementary products, metallurgical testing and modernisation services. FLSmidth offers you a complete line of equipment and services with proven reliability and enhancing performance from the leading brand names of Krebs, WEMCO, EIMCO, Dorr-Oliver, Pneumapress, Moller, Vecor, ABON, RAHCO, Buffalo, Meshcape and Conveyor Engineering.

and were able to complete this project in only 10 weeks from the initial date despite these harsh conditions.”

axolution is an innovative new solution based on recent global trends and developments in materials handling, and adds substantial value to the mineral processing industry higher up the value chain. According to Sew-Eurodrive general manager communications Rene Rose, industrial gearboxes and motors are ideal for bulk materials handling, but are limited in their functionality when processed material becomes valuable. “This processed material would be the actual gold and platinum, for example. To reduce the potential for pilfering, human handling should be limited with the higher-value commodities, and this is where Maxolution comes into play,” she explains. The trend in the industrial environment is a move away from conveyor belts that just move products from ‘A’ to ‘B’, and instead having an item or station that moves from ‘A’ to ‘B’. Although standard in the automotive industry, this technology is brand new to the local mining industry. This technology comprises wireless communication and inductive power transfer systems. Instead of having cable trays or busbars to transfer power to the mobile solutions, Movitrans offers contactless energy transfer system. “Here, electrical energy is transferred from a fixed conductor to one or more mobile consumers, without contact. Instead the electromagnetic connection is made via an air gap, which means it is not subject to wear-andtear and is therefore virtually maintenancefree,” she states. This type of power supply is also emissionfree and resistant to contamination from external sources. In addition, the wireless communication is shielded in order to prevent loss and interference. An Automatic Guided Vehicle (AGV) utilises inductive power supply in the form of transfer cables embedded into the floor. One of these is a leakage cable, which provides the communications. The AGV boasts a built-in safety feature that slows it down when humans are near its path. Rose notes: “This safety concept is based on a scanner that will detect any people in the vicinity, whereupon it will switch off and enter a ‘safe’ mode. Enquiry No: 27

October / November 2014

KZN Industrial & Business News

materials handling, bulk handling & logistics

Your lifting tackle - is it legal or lethal?

ll lifting equipment, must be regarded as safety critical items in the work place. It is therefore essential for all users that conduct lifting operations, to have a Safe Lifting Programme in place. This will ensure legal compliance with the various Lifting Equipment Regulations of the OHSA and MHSA, as well as conformance to International quality standards. In addition to lifting, lowering and stacking loads properly and safely, the service life of lifting equipment will be extended if properly used, maintained and inspected. Management need to implement and comply with a Safe Lifting Program in the work place which includes the following elements: • Ensure correct type and size of equipment is used for all particular lifts • Train all operators to use this equipment correctly and safely • Inspect all equipment regularly and properly by trained inspectors • Keep all registers, certificates, appointments and documentation in order • Implement and maintain a scheduled maintenance program • Store equipment correctly when not in use • Comply with applicable OHSA or MHSA Lifting Equipment Regulations and also have a written SOP or Works Procedure for lifting operations Because of the inherent dangers involved in lifting operations, only top quality slings and hoists, supplied by distributors of OEMs must be used. This is important, not only to verify the supply and use of quality lifting products, but also for traceability to the OEM for his support , should an enquiry arise. DMR 18.10 (e) of the OHSA requires that all lifting tackle must be visually inspected, (not tested) at intervals not exceeding three months, by a trained appointed lifting tackle inspector, known as a LTI. The results of these

Top employer 2015 in Africa

HL Express SSA has been certified as a Top Employer in Africa for its outstanding employee offerings across the region. This is in addition to six African countries - South Africa, Nigeria, Kenya, Uganda, Ethiopia and Ghana that were also certified Top Employers in their local markets. Independent research by the Top Employers Institute shows the company looks after its people exceptionally well and DHL Express is one of the select few companies to achieve the exclusive Top Employers Africa 2015 certification in various African regions in which they operate. According to Charles Brewer, MD of DHL Express Sub Saharan Africa, this achievement is an acknowledgement of the business’s strong focus on employee engagement, development and training on the African continent. Top Employers is a global and annual programme that certifies organizations which successfully demonstrate exceptional HR environments and employee offerings. The programme is an audited and research based process that assesses employee offerings as well as the conditions employers create for staff to develop. Brewer says that this accolade is testament to their dedication of having motivated employees, which is a key focus pillar of their strategy. “Understanding the need to drive a common culture across 220 countries, we launched a Certified International Specialists training program for all 3,500 staff in Africa. Everyone from the Global CEO to a Courier in any country has gone through this training program reinforcing our core competencies as an organization. CIS training has been central to our staff retention and development globally.” The Top Employers Institute assessed DHL Express’ employee offerings on various criteria, including talent strategy, workforce planning, employee on learning & development, performance management, leadership development, career & succession management, compensation & benefits and company culture. Crucial to the Top Employers process is that participating companies must meet the required high standard in the research in order to achieve the certification. Only organizations that achieve certification in at least four countries within the region deserve the special Top Employers Africa 2015 recognition. The independent research has verified DHL Express’ outstanding employee conditions in all certified countries. Enquiry No: 29

inspections must be recorded in proper registers, which must be available for scrutiny by an auditor or DOL Inspector. The LTI can be an in house appointed person or a contracted service provider. All LTIs must be appointed in writing by the employer. Apart from regular pre use and periodic visual inspections, all lifting machines and hoists, including chain blocks and lever hoists, must also be load tested annually by a company that is registered with the DOL as a LME. The inspector who conducts, or supervises the load test, and signs the LME certificate is a LMI and he must be registered with ECSA. The scope of work of the LME appears on his DOL certificate.

The type of lifting machines that the LMI can test, must be verified by ECSA. It is important to note that lifting tackle, including slings must not be load tested in use. This is in fact illegal. Lifting tackle and hoists must be supplied with either a Test Certificate or Conformance Certificate. Test certificates must be properly worded with WLL, actual test load applied, date of test and person conducting the test, whereas conformance certificates must specify the Standard to which the sling or component conforms, such as a SANS, EN or DIN etc. All users of lifting equipment should compile and implement a proper Standard Operating

Procedure (SOP). This SOP is also applicable to contractors working on site with cranes, hoists and slings. Furthermore, proper Risk Assessments and Rigging Studies or Lifting Plans must be in place for the different types of production, maintenance or construction lifts. Lastly, lifting equipment are safety critical items and price must not be the deciding factor when these items are purchased. Phakamisa Safety Consultants offer various lifting equipment training courses, conduct plant inspections and audits, compile and assist their clients to implement written SOPs and provide inspection and stores control regEnquiry No: 28 isters.

materials handling, bulk handling & logistics

October / November 2014

KZN Industrial & Business News

Handling coal efficiently B LT SA supplies a range of robust bulk handling equipment that provides efficient solutions for the handling of minerals and concentrates in diverse industries, including the coal mining sector. “Samson automated handling systems offer reliable performance from truck intake, using the Samson surface feeder - to mobile stacking and ship loading solutions,” says Keith Dowie, project development manager for BLT SA’s Samson bulk materials handling equipment. “Reliable handling equipment plays a critical role in complex logistic operations required to deliver materials on time and to specification, with minimal environmental impact.

“Economical transportation of coal demands the efficient use of rail, road and sea shipment for long distances, with truck or conveyor haulage for short runs at the mine or quarry.” “Samson handling equipment is known globally for flexibility, with no compromise on performance, environmental standards, reliability or safety. These systems, which require minimal civil works, are designed to join together fixed and mobile equipment, providing a cost efficient alternative to fixed bulk handling installations. Operating costs and maintenance requirements are significantly lower than with conventional materials handling systems.”

Samson’s Stormajor radial boom stacker combines the benefits of the Samson material feeder unit with a radial outloading boom, into a single mobile unit that is able to receive material from tipping trucks and loading shovels. The buffer holding capacity of the integral Samson receiving unit enables efficient truck unloading during tipping truck deliveries. Material is drawn from the tipping truck in a controlled stream, which means dust generation is significantly reduced, minimising environmental pollution. With the radial boom feature, this fully integrated machine is able to efficiently create economical stockpiles, with minimal machine movements. Using a hydraulic cylinder in tension, a wide angular range may be accommodated allowing the boom

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Rugged spools, with four control lands and twenty one spool configurations available Solenoid, lever, cam, air or oil pilot operated Soft-shift available on NG6 and NG10 solenoid operated valves Low pressure drop 8 Watt for D1 available Available in both AC and DC and the voltages Several solenoid connections available

the belt width of the out loading boom conveyor. A belt width of 800 mm offers a handling rate of 450 m³/h, a 1 000 mm width belt has a 4750 m³/h rate and a belt width of 1 200 mm offers a rate of 1 250 m³/h. These units have various specification options suitable for handling different materials, from cereals to heavy mineral ores. Enquiry No: 30

Multi-modal logistics hub

ith the move of its freighters to DWC, Emirates SkyCargo, the freight division of Emirates, has strengthened the link between Dubai International and DWC, through its trucking operations, reinforcing the city’s multi-model logistics capability as a growing and popular global cargo hub. Emirates SkyCargo launched its trucking operations on 1 May 2014 in tandem with the start of its freighter operates at DWC, and up until 1st September 2014 its fleet of 47 trucks has facilitated the transhipment of over 108,000 tons of various commodities from perishables to outsized cargo between Dubai International and DWC, recording over 17,000 round trips, 24 hours a day, seven days a week. Dubai ranks sixth globally, measured by air cargo traffic and is one of the fastest growing cargo hubs in the world. Its central position, coupled with the growth of Emirates airline, and increased popularity of air cargo transportation, saw cargo volumes reaching record levels in 2013 with 2,435,567 tons of air freight passing through Dubai International, up 6.8% compared to 2,279,624 tons recorded during 2012. Over 125 airlines serve

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to be lowered almost horizontal. This system allows material with a low repose angle to be stockpiled at steep conveyor angles, without material engulfing the main axle wheels. A single machine may be used for different stockpile areas handling different materials, with minimal capital investment. There are three capacity ranges of the conveyor, which are based on

Directional Control Valves

the two airports in Dubai, facilitating the movement of passengers and cargo to and from 260 destinations across six continents. “Our decision to move freighter operations to DWC was a strategic move that enables us to better tap and support Dubai’s growth. We now have a dedicated facility for our freighters which allow us to grow our fleet size and meet our growth requirements,” said Nabil Sultan, Emirates Divisional Senior Vice President, Cargo. Emirates SkyCargo signed a fiveyear trucking contract with a Dubaibased land transportation service provider for its fleet of trucks which consists of: 12 reefer trailers designed to

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handle all temperature sensitive commodities such as perishables, flowers, and pharmaceuticals; 33 dry boxes for all general cargo; and two low bed trucks for handling outsized cargo including aircraft engines, cowlings, and machinery. Each of the reefer trailers and dry boxes has the capacity to accommodate up to 28 tons. These trucks move on an inclusive geo-fenced corridor to maintain the speed of connectivity and achieve on time performance goals. A central control room monitors all real time movements as trucks are equipped with a vehicle tracking system and a remote electronic locking system which allows for observation of the security of the vehicles and the sterility of the cargo therein by alarming and altering any en-route deviations. Emirates SkyCargo DWC terminal is equipped to handle 700,000 tons per year, and features advanced technology, including a fully automated material handling system which is one of the world’s first to have an automated Unit Load Device (ULD) that enables quick transfer of six ULDs simultaneously. Enquiry No: 31

40 years in the minerals processing industry

rom screens to cyclones and chutes, Multotec’s ongoing focus is to reduce the operating costs of mineral processing plants. “The efficiencies that we can introduce for our customers are tangible and can have a major impact on the bottom line,” Thomas Holtz, Multotec CEO, says. As Multotec celebrates its 40th anniversary this year, Holtz reflects on how far the group has progressed in adding value to its customers’ businesses. From its humble beginnings as a manufacturer of polyurethane screen media for the mining industry, today it designs, builds, manufactures, installs and maintains equipment across the entire value chain. “While many companies end up having to source products or design services elsewhere, Multotec has a lot of these resources in house. We also pride ourselves on the fact that many of our expert sales people hail from metallurgical or mining industry backgrounds,” Holtz says. Multotec’s focus is to reduce the operating costs associated with mineral processing plants, and this is across all commodity sectors, from diamonds to coal, gold, platinum and phosphates. Such a diverse focus has given Multotec extra stability and traction in the present economic downturn. “The mining industry is currently in a downturn as we know. The challenge as an equipment supplier under these circumstances is to stay financially viable, grow market share and prepare for the next upturn, which will come. If anything, the business environment has become more volatile, meaning that equipment suppliers such as Multotec have to be more flexible and agile,” Holtz Enquiry No: 32 comments.

October / November 2014

materials handling, bulk handling & logistics

KZN Industrial & Business News

The complete forklift solution

Cutting the cost of costly containers

Sagie Govender, Import Manager (Project and General) at Turners Shipping and Sylvester Moodley, Transport Manager

t is a well known fact that a significant portion of the price of goods, particularly fast-moving consumer goods, can be attributed to the cost of the transport in getting products to their point of sale,” says Sagie Govender, Import Manager at Turners Shipping. “There are also some cost saving practices which, although known to people in the logistics business, are not used as often as they could

Richard Gibbs, Sales and Marketing manager for FMS Technology with Riaan Pienaar Business Development Manager for MiX Telematics

MS Technology recently partnered with MiX Telematics (Pty) Ltd to supply a complete solution to forklift truck management, which will also enhance safety, control & cost cutting solutions. MiX Telematics are arguably the leading provider of fleet and mobile asset management solutions, with a global footprint in 112 countries across 6 continents. Being new to the materials handling industry the company realised that in order to effectively penetrate the industry, they would need to partner with an expert in this field. FMS Technology was the obvious choice with over 20 years’ experience. The partnership effectively places FMS Technology in the forefront of forklift management, control & safety enhancement. “We are able to offer a complete solution, for any application” says Andrew Sym, owner of FMS Technology. “Each customers needs are different and we can provide the full solution for every aspect of the materials handling industry under one roof. Whether the requirement is for a rental fleet where basic hours and critical events are needed or for the warehouse manager needing to keep track of production, drivers and costs, we have a solution. “ “We have been providing cost cutting and safety solutions to OEM’s and end users for more than 20 years, with services which include speed control, gear control and engine management. By adding the MiX Telematics products, with specialised operator and machine reports tailor made for materials handling, we now provide the complete solution for any application.” The new materials handling solution provides entry level cost effective reports and transmission protection and engine management for a hire fleet. This can be easily upgraded to a full management solution at minimal cost. Basic and detailed analysis of forklift use is available in real time. This specialised materials handling solution, managed by FMS Technology, heralds a new era in forklift control and Enquiry No: 34 management.

Do you have an Enquiry? All articles end with an enquiry service number. Readers are encouraged to complete the form on page 43 should further information and contact details be required.

be.” One such option is to convert freight to break-bulk and transport it on the more efficient tautliner. Up to 70% of freight in South Africa is being transported by road and most of the imported goods are transported in the containers in which they arrived. Govender says that while containers are an efficient mode of transport for sea freight, “it is a different story when the goods arrive and have to be transported by road.” Generally trucks can only carry two containers but by unpacking the freight the same size truck can carry the equivalent of three containers of break bulk. “In this way the customer saves on the cost of returning the empty containers to the yard and is moving more freight per trip. Using this system savings can be as much as 25%.” “We have been offering this option to some of

our customers and the response has been very positive. By transferring the freight to a tautliner off-loading at the destination is easier and more efficient. The truck can be off loaded from both sides and, unlike a container delivery, there is no need for there to be a ramp at the destination,” explains Sylvester Moodley, Turners Shipping’s Transport Manager. “There is no time spent repositioning containers either,“ he adds. “It is up to the logistics managers like us to find innovative ways of cutting costs and becoming more efficient. “As the cost of imported diesel rises and pressure on the road network increases I suspect more customers will look at options like this. Getting deliveries in a container has become a habit, but one that circumstances might force use to change.” Enquiry No: 30

October / November 2014

materials handling, bulk handling & logistics

KZN Industrial & Business News

Major empowerment deal

eba Chute Systems has successfully concluded a major empowerment deal with Hlanganani Capital that will see the company that pioneered the Weba Transfer Chute System for bulk materials handling in the mining industry gain further traction in Africa and other emerging markets such as South America. In addition to the empowerment deal, Weba Chute Systems has announced an overhaul of the company’s executive management structure that will see the eventual retirement of founder and Weba inventor Werner Baller. Farouk Abrahams from Hlanganani Capital becomes a director of Weba Chute Systems in order to boost the existing roles of Mark Baller as MD and Alwin Nienaber as Operations Director. “We wanted a partner that could bring value to the company. We shopped long and hard until

BMG-MAT08102014-KZN.ps E:\!BMG\#Jobs\Adverts\2014\102014\BMG-MAT08102014-KZN.cdr 08 October 2014 07:58:54 AM Color profile: Disabled

we found this group,” Baller says. Hlanganani Capital is a black controlled private investment and advisory entity primarily focusing on arranging, participating in and managing private equity investments mainly in the mining, engineering and related service sectors. It focuses on delivering significant shareholder value through sound strategic investment practice while contributing to the transformation of the economy and society at large. Hlanganani Capital was established by Rowan Smith, Farouk Abrahams, Anton Millar and Olivier Barbeau with the strategy to invest on a partnership basis in a diversified portfolio that takes advantage of the growth prospects offered in sub-Saharan Africa. The investment focus is on true private equity investment and then to focus with management on utilising a vast network including other inves-

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Quality Components

Technical Expertise

Superior Service

PART OF THE PROCESS

Materials Handling Solutions That Deliver. BMG offer a complete range of products for materials handling applications - from belting, motors and drives through to bearings, seals and couplings. In addition to our range of product solutions, we provide valuable insight in to the technical requirements of your operating process as well as foresight as to how our technical expertise, design and onsite maintenance capabilities and training can all be applied to maximize your production efficiencies.

tors to maximise the value of the investments for all stakeholders. In addition the focus is also on equity investments with a longer term investment horizon. “What we liked about the group is that it is very hands on,” Baller says. “While they do not partake in the day to day running of the company, they set up meetings with potential clients as well as bringing clients to the table. They are proactive and willing to dispense advice and want to help grow the business. They are keen to add value and not just reap the benefit.” The empowerment deal followed the decision by Werner Baller, the original majority shareholder of Weba Chute Systems, to transform the company into a fully compliant Broad Based Black Economic Empowerment (BBBEE) entity that also fulfils the obligations of the Mining Enquiry No: 35 Charter.

Year-on-year growth T he South African truck market has continued to show resilience against the backdrop of low economic growth, interest rates hikes and inflationary pressures. Although the total sales for September show a slight 2.80% decline on the previous month’s results, the year-to-date figures have been more positive, growing 1.54% to a total of 23 347 units. This is according to the latest combined results released by the National Association of Automobile Manufacturers of South Africa (Naamsa), Associated Motor Holdings (AMH) and Amalgamated Automobile Distributors (AAD). “The growth in new truck sales was achieved on the back of above average growth in the Extra Heavy Commercial Vehicle and Bus segments,” explained Rory Schulz (pictured), acting managing director of UD Trucks Southern Africa. “The strength in EHCV sales, together with the improved business confidence index reported in August, have certainly been encouraging and point to an improvement in investor sentiment.” During September, both the EHCV and BUS segments continued to impress, growing 8.67% and 14.90% on a year-to-date basis,

and concluding the month on 10 540 and 902 units respectively. On the other hand, Medium and Heavy Commercial Vehicle sales both declined over the course of the year when compared to the same period in 2013. The MCV segment lost 6.64% to stand at 7 997 units at the end of September 2014, and HCV ended the period on 3 908 units, a slight 0.91% decline. “The outlook for the rest of the year is cautious but optimistic, with possible interest rates hikes and vehicle price increases expected to contribute to a difficult trading environment,” said Schulz. “However, the industry’s resistance despite these challenging conditions is also a true testament to the character and resilience of all involved in trucking.” UD Trucks experienced three good quarters so far during 2014, growing their overall sales by 5.8% compared to the 1.54% rate of the total market. The company’s Quon range continued to make big inroads in the market, growing 25.56% YTD. Its classic MCV range, which is currently in its run-out year, also experienced a growth spurt of 4.88% on a year-to-date Enquiry No: 36 basis.

Modern service for rail vehicles

1974-2014

nder the heading “Systems Service” Voith will in future offer a comprehensive maintenance program for components and rail vehicles at its location in Kiel, Germany. The modern services cover a broad spectrum: from overhauls and repairs of components to systems integration, approval of additional functions and the general refurbishment of diesel vehicles. Exchange pools for overhauling transmissions or Scharfenberg couplers within strictly defined and guaranteed time windows are already among the service offers from Voith. With general overhauls of locomotive and railcar components Voith goes one decisive step further at its location in Kiel. The offer of exchange pools is substantially increased in accordance with the wishes and the requirements of the customers – from transmissions, couplers and gear units to

entire exchange bogies. In future it will even be possible to remove and re-install the bogies within one day. Thanks to the availability of exchange units, the refurbishment of the components is not Enquiry No: 37 time critical.

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October / November 2014

KZN Industrial & Business News

materials handling, bulk handling & logistics

Local company spreads its wings

artn e rs h ip for to always select the service Development, Integration and provider with a proven track Industrialization is the growing record ensuring profitable vision of the BRICS (Brazil, Russia, results and displaying innoIndia, China & South Africa) assovation for many more busiciation of major emerging national ness opportunities. economies. Value Logistics Ltd and Value Logistics boasts Weida Freight System are healthover 30 years of experiily contributing to this, catalyzing a ence in the Transportation stronger relationship between China Industry, complimented by and South Africa. Weida Freight System’s Weida Freight System, a Chinese two decades of experiforwarder and customs broker, ence and knowledge of the together with Value Logistics Ltd International Transportation have entered into a joint venture, Industry - a perfect partleading to Value Logistics opening nership for all international an office in Hong Kong. logistical requirements. Stephen Segal, Director for Value’s Clearing and As of 2010, China is South In addition to an office in Africa’s largest trading partner. With Forwarding division (left), concluding the partner- Hong Kong, Value Logistics both South Africa and China being ship with Weida Freight System at their Head Office have joined a strong in Hong Kong members of the BRICS association, International network of forthis kind of joint venture will result warding agents with over in benefits for these two developing Freight Systems who have offices 580 offices in 182 countries economies, naturally creating employ- internationally, including the USA, providing representation in almost ment and migration of new systems, opening growth, networking opportu- every country in the world allowing administrations and technologies. nities and assisting Value Logistics Value Logistics to offer Clearing & Value Logistics is proud to be in broadening their horizons to reach Forwarding services to and from anyextending their supply chain solu- higher limits. where in the world on a door to door tions internationally. This is enabled With today’s competitive ethos basis. Enquiry No: 38 by Value Logistics’ new partner Weida across all industries, it is imperative

Haccp food safety handling

ew food production and processing practices, coupled with emerging food borne pathogens and changing eating habits and demographics have all contributed to an increased awareness of food borne illness. In order to be able to effectively address safety concerns, the food and beverage industry has adopted the Hazard Analysis and Critical Control Point (HACCP) system, an internationally recognised food safety system that assists with the manufacture of safe food products. In keeping with this latest trend to prevent, reduce or eliminate potential biological, chemical and physical food safety hazards, Apex Strip Curtains & Doors has announced that all its products are HACCP compliant. Strip curtains play a vital role in the food and beverage industry and therefore have to be durable and flexible in preventing the ingress

of unwanted elements. This requirement is critical in the light of issues such as crosscontamination. From production facilities to retail outlets, the food and beverage industry depends on strip curtains to minimise the entrance of dust and heat while at the same time facilitating easy access for personnel and vehicular traffic. “After extensive research, we devised a specially formulated PVC material that retains its flexibility even after years of use. In addition, the transparency of the material ensures optimum visibility and safety,” Dessing explains. The patented Balledge design provides an effective thermal seal while at the same time parts easily under pressure to allow people and goods to move through unhindered. The Balledge design consists of a reinforced edge on the border of each strip that not only prevents snagging or scratching of goods or people but also extends strip life. Enquiry No: 39

Performance monitoring system

owafix, a leading supplier to the paint, building and allied trades, has implemented Econz Wireless Timecard Lite employee tracking system to track and monitor the performance and productivity of their merchandisers in Johannesburg and Durban. “Our merchandisers are strategic to our business,” says Powafix Regional Sales Manager Joel Poilly. “They visit our customers to provide their staff with knowledge of our range of products, check shelf layouts, promotions, and stock levels, which is then passed to our Account managers who follow up with orders.” Powafix provides a wide range of locally manufactured chemicals and solvents used in the timber, building, paint and DIY sectors at national chains such as Builders Warehouse, Mica, Jacks Paint, Timber City, Pennypinchers, etc. These products are used both by professionals and consumers. “Before we implemented Timecard Lite, we had no idea if our merchandisers in the field were starting on time, visiting their allocated stores and not only transferring product knowledge to the store staff, but checking stock levels, promotions and product display. With Timecard Lite we not only now know when they start their work day, but are getting positive feedback from store managers and seeing an increase in orders,” says Poilly. Powafix decided to implement the solution by giving their merchandisers new smart phones with the application already installed, and after a very small amount of staff training, was immediately effective. “The staff involved found Timecard Lite very easy to use, and were not resistant at all to Enquiry No: 40 its use.”

Manufacturers of Safe & Reliable Lifting Equipment

www.cmcosa.co.za

materials handling, bulk handling & logistics

ectra Automation, has donated a TS2 Conveyor System to the Electrical, Electronic and Computer Engineering Department, Faculty of Engineering and Information Technology, at the Central University of Technology (CUT) Free State, for an ongoing research project on reconfigurable assembly systems. “The idea behind this is to continuously

October / November 2014

KZN Industrial & Business News

Conveyor donated for research

discover solutions to overcome potential and existing challenges,” explains Professor Herman Vermaak, acting Dean of the Faculty of Engineering and Information Technology, CUT. “As research questions arise, our students

MEET THE FAMILY

will redesign and modify the system, attempting to find answer to these continuing real life challenges.” Prof. Vermaak says that post-grad (Masters) and B-Tech students conceptualised and designed a conveyor system of their own, which was then developed and assembled by diploma students undergoing their experiential training with the department’s research group. “This existing system was successfully used and upgraded when necessary,” he says. “However, when we started the Reconfigurable Assembly Project it became necessary to acquire a conveyor system that was able to contribute towards an intelligent system. As the TS2 Conveyor System from Tectra Automation is modular, easy to operate and allows for control via different options and protocols, it is the ideal conveyor system for this projec. Prof Vermaak explained.”He points out that the rationale behind the project is for the system to be used within some of the courses already offered at CUT, ensuring that all students in the department get the opportunity to work on it before completing their respective courses. “Added to this,” he says, “training with this system will form part of the Control and Digital courses within our new qualifications framework.”

As the reconfigurable systems developed by the students can be used in a number of real world applications – from assembly systems to quality control and component handling, including component classification systems – it gives students the opportunity to think within the environment of real world applications, from filling systems to quality control systems. “Students will be in a position to develop new systems on paper and then, using software provided by Tectra Automation, create the virtual system,” Prof Vermaak explains.” Enquiry No: 41

Sealing arrangement for scraper conveyor idlers

Our combination of multi-faceted handling equipment means that Linde machines are perfectly equipped for big jobs, small jobs and everything in between. With our comprehensive logistical know how, Linde has fast become the industry symbol for superior quality, seamless functionality and innovation. Available to lease, rent or on hire purchase, investing in Linde machines ensures the remarkable efﬁciency of each member of our family. For more information on Linde dealerships, products and services contact us on Tel : 27 31 716 7460 or visit www.linde-mh.co.za

Linde Material Handling

n electricity supplier was experiencing frequent breakdowns of their submersible scraper conveyor (SSC) idlers and looked to SKF South Africa for a solution. SSC idlers are used in the boilers of coalpowered power stations to remove ash from the boilers. “As these recurring breakdowns were leading to costly downtime it was vital for us to find the best solution as quickly as possible for the electricity supplier who is a longstanding SKF customer,” stresses Andre van Loggerenberg, SKF Junior Project Engineer. The solution offered by SKF was an improved sealing design consisting of an SKF custom-designed sealing arrangement. “To perfect the design, the units were submitted to several design reviews in order to obtain the optimum operating performance for the customer,” explains Van Loggerenberg. “Our sealing arrangement maximises bearing life and extends idler operation by several months compared to the customer’s previous idlers. “In fact,” says Van Loggerenberg,

“The operating life of the unit increased from four to eight weeks to an incredible 18 months, which is a vast difference. Ultimately, this leads to vastly improved uptime or operation time for our customer.” In addition to minimising contamination ingress, the design, according to Van Loggerenberg, also allows the customer to re-use some components when units are reconditioned. The success of SSC idlers, with all the related cost saving benefits, serve as a foundation to present similar arrangements to a sister plant which promises great potential for future business opportunities for SKF. Building strong customer relationships are important to SKF. “This project has without any doubt strengthened both SKF and SKF authorised distributor, Bearing & Transmission Newcastle’s relationship with the customer,” concludes Van Loggerenberg. Enquiry No: 42

Real time data on-board monitoring

ooyco Electronics’ state-of-the-art on-board monitoring device is fitted to underground mining equipment to measure a spectrum of parameters that affect both equipment and operator. These include detailed, accurate and realtime data indicating the operating, standing and idle hours of vehicles, the percussion running hours of drill rigs and roof bolter machines, as well as machine abuse. The ability to monitor the percussion hours of a piece of machinery provides management with detailed information on how many hours the drill bit worked, as well as the actual production hours of the machine when the percussion was running and the amount of vibration to which the operator was subjected. To avoid driver fatigue, this innovative on board monitoring technology can also be configured to automatically shut down machines at pre-set intervals and only allow them to be restarted once the rest period is over. Detailed reports of the various data are accessed via a fixed reader connected to a fibre optic backbone that is linked to a server on the surface, or via a portable tablet or PC fitted with a reader. Booyco Electronics is a single source market leader that supplies quality specialised electronic safety equipment, including collision intervention systems. Enquiry No: 43

October / November 2014

KZN Industrial & Business News

materials handling, bulk handling & logistics

Coated belts for food

ew to BMG’s range of Food Grade belts, which comply with stringent EC and FDA requirements for pristine hygiene standards in the food and beverage sector, are Silicone and PTFE coated process and conveyor belts and folder gluer belts. “There are many applications in the food processing sector where standard process or conveyor belts cannot be used,” says Ryan Forsyth, divisional manager, BMG’s light materials handling division. “It is critical in modern food processes, that only high quality coating materi-

als suitable for direct contact with foodstuffs, as well as for packed food conveying, are used to ensure hygienic and safe processing and efficient logistics.” “Ammeraal Beltech’s new Food Grade Peak process and conveyor belts and Rapplon FDA approved folder gluer belts for contact with dry foodstuffs, enhance BMG’s portfolio of products suitable for the food industry.” The Peak range of Silicone and PTFE coated process and conveyor belts, which has been developed for various baking processes, can

withstand high working temperatures up to +260°C, with resistance to working cold temperatures down to -70°C. These low friction belts, with high abrasion and corrosion resistance, have excellent release properties – even for sticky foods, like flour and sugar based products. Baked goods are transferred easily and undamaged, reducing mess and waste in all processing cycles. Peak belts are also suitable for press baking products (such as pizza bases, flat breads and tortillas) and for open-flame baking lines for the production of certain breads.

This range is also designed for use in cryogenic freezing. This new food technology has advantages over traditional mechanical food freezing lower set up costs and improved food quality. The open mesh design of the Peak range ensures an optimal airflow and the PTFE coating enables easy cleaning for enhanced hygiene. BMG’s new Rapplon folder gluer belts, with non-glazing Food Grade covers that comply with EC and FDA standards for contact with dry foodstuffs, ensure precise transport and folding of carton blanks. These folder gluer belts, which are available in 3 mm, 4 mm and 5,5 mm thicknesses to fit most folder gluer machines, provide a firm grip on all

“Innovative products like the Water-Cooled Third Generation Brake reduce costs and increase productivity, demonstrating Eaton’s dedication to providing safe, reliable and efficient braking solutions for our customers in Africa,” said Emil Berning, General Manager for Hydraulics, Eaton Africa. Standard features of the brake include corrosion resistance for harsh marine environments, wear spacers located at the front for easy access and maintenance and new sealing technology to eliminate water leakage. The industryleading water cavity helps increase the thermal rating by 50 percent while achieving greater flow with lower pressure drop. Up-front-investment costs can be reduced in some applications where the increased energy capability allows for a smaller brake to be used. In drawworks applications where the higher energy is applied, the WCB3 allows up to 54 percent faster drilling while tripping into a hole for an average savings of $10,000 per operation. In addition to these features, the WCB3 has two plates to eliminate the outboard mounting support for significant ease of Enquiry No: 45 design and cost reduction.

types of board for accurate carton blank movement during folding, gluing and packing. These perfectly straight belts ensure reduced energy consumption, extended service life and fewer maintenance stops. Other features include abrasion resistance and low operating noise. Enquiry No: 44

Top Guns competition

Water-cooled third generation brake

ower management company Eaton today announced the launch of Eaton’s Airflex WCBD3 and WCSB3 WaterCooled Third Generation Brake in Africa, this is a disc type, water-cooled dynamic tensioning brake designed to keep oil, gas and mining operations up and running. The latest custom design helps dissipate extremely high thermal energy loads experienced in applications like drawworks, marine winches, cranes, metal processing and dynamometers. The brake’s improved internal design allows for faster drilling and gives original equipment manufacturers (OEMs), distributors and end users the ability to downsize their brake, saving up to $60,000 a brake installation. The third generation in Eaton’s innovative Airflex product line, the latest innovation integrates seamlessly with other brakes in this product line. Equipped with backward compatibility into existing WCB/WCBD/WCSB applications, improved wear adjustments and increased brake size horsepower rating (650 to 1,000HP per plate), it is longer-lasting and better performing than existing watercooled brakes. It is also easy-to-replace and maintain and more cost-effective than competitive-style brakes in Africa.

nternationally-recognised manufacturing and engineering company DCD recently hosted its second annual Top Guns competition for welders, forklift drivers and crane operators, with the aim of motivating employees to improve their skills within their specific field. DCD Protected Mobility was this year’s host, and general manager Andrew Mears noted that the competition was evidence of the company’s commitment to internal skills development. “This iwas the main focus of the day, as skills development is a big issue for DCD and is something that the entire Group is trying to enhance. Whether it is a welder, forklift driver or crane operator, this competition judges how safely they perform their tasks, and the skill with which it is carried out.”

Safety is of the utmost importance throughout the various DCD business units. This extends to the customer and the product, as well as to the safety of where the staff work, how they work, any protective clothing that may be needed, and the safety procedures that are in place. In addition, there is also an aspect of technical competency. The Top Guns competition promotes employee safety, in addition to the quality and finish of the final product. “We place a strong emphasis on internal skills development, with this competition serving as the catalyst for encouraging personal growth and quality development within DCD. Internal development also helps DCD to continue its drive to create local content thresholds in the various manufacturing sectors of South Africa.” The Top Guns competition is run in partnership with three sponsors, Afrox for welding, Toyota Forklifts for the forklift section, and FB Cranes for the crane portion of the competition. These sponsors were responsible for setting up the respective stations of the competition, as well as judging the competitors, and sponsoring prizes for the winners. Enquiry No: 46

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October / November 2014

materials handling, bulk handling & logistics

KZN Industrial & Business News

KZN crushers’ faith consistently rewarded

waZulu-Natal based Ballito Crushers (Pty) Ltd, is a long-time supporter of Sandvik crushing and screening equipment citing the product’s inherent quality and

productivity. This loyalty has been rewarded by its recent purchase of a Sandvik QJ341 tracked jaw crusher which is exceeding expectations in terms of performance and flexibility.

Pilot Crushtec International national sales manager Nicolan Govender explains that the machine was purchased in July in order to produce large volumes of 0-80mm dolerite material for use in a major construction project. “In this particular application the QJ341, using its smallest 50mm closed side setting, is producing material to the required specification in a single pass. This process has previously been regarded as at least a two-stage operation, necessitating the use of an additional lower capacity crusher or screen, or quite possibly both,” he says. The savings in operating costs has been further boosted by the QJ341’s ability to deliver in spec material at a rate of 300 tons per hour, which the customer estimates to be a 30% improvement on the output of the product’s predecessor. As the official Sandvik Construction distributor for southern Africa, Pilot Crushtec International prides itself on maintaining a comprehensive stock of finished products and spares. This is reflected by its ability to place the QJ341 on site just north of Ballito in under a week from receipt of order. Clive Damant, founder and director of Ballito Crushers, has been using Sandvik crushing

equipment since 2006, for the simple reason that he regards it as a brand that produces reliable products. “Sandvik produces very, very good equipment and the service in respect of parts and technical back up is first class. Our new QJ341 is performing well and appears to be an excellent machine,” he says. The delivery of the Sandvik QJ341 follows close on the heels of Ballito Crushers’ purchase of a Sandvik UJ310 semi-mobile jaw crusher at the end of 2013 and reflects the upbeat pace of infrastructural development in the region. “We are kept very busy working in our own little local economy which is proving to be one of the fastest growing regions in South Africa Enquiry No: 47 today,” says Damant.

RFID systems

he constant increase of automation in modern production plants is increasingly supported by identification systems. Their tasks include, for example, the control or release of production steps or the assignment of information about each product. The RF identification system from ifm electronic is a compact and easy alternative for applications in which, for example, optical identification is not possible due to the ambient conditions. The RF identification system for AS-interface allows reading and writing of code carriers (ID tags), benefiting from the advantages of AS-interface. It can be easily integrated into existing AS-i networks and is immediately ready for operation. For reading, the RF identification system uses the AS-i analogue protocol 7.4 for data transfer. Special software modules are not required. Up to 31 read/ write modules can be connected to one AS-i master. The read/write head stores transmission

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09.07.14 10:08

SKF South Africa - Celebrating 100 Years of Innovative Solutions

Linear Motion Solutions Linear motion products from SKF combine the knowledge and efforts of linear drive systems (ball and roller screws) and linear guides and tables. Linear drive systems typically use screws to transfer rotary into linear movements. This requirement is well achieved by our high efficiency driving products: miniature and large rolled ball screws, ground ball screws as well as different variations of roller screws. The second part of Linear Motion are linear guides and tables. To provide the best fit for your guiding needs, SKF’s comprehensive range includes linear ball bearings, profile rail guides, precision rail guides and linear tables and slides. SKF South Africa is celebrating 100 years of innovative solutions during 2014. Drawing on five areas of competence and application-specific expertise (bearings and units, seals, lubrication systems, mechatronics and a wide range of services), SKF brings innovative solutions to OEMs and production facilities in every major industry worldwide.

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errors which can be retrieved for a targeted fault analysis. Antenna, electronics and AS-i interface are integrated in a compact housing. The voltage is supplied via the AS-i network via a rotatable M12 connector. No additional operating voltage is required. The ID tag (transponder) provides flexible mounting options for workpiece carriers, tanks for example. The code length is 15 bits. The RFID system (Radio Frequency IDentification) generates a 125 kHz electromagnetic field for reading and writing of data. The electromagnetic field emitted by the antenna induces voltage in the passive ID tag (transformer principle). This activates the ID tag (transponder) which returns its code. Processing of the code and transmission to the AS-interface are carried out in the read/write head. The advantages when using the system include reliable data transfer in dynamic reading processes and very small ID tags. Ethernet, Profinet, and Profibus evaluation Enquiry No: 48 units are also available.

Lifting the light truck industry ince its international launch, the latS est Fuso Canter Lift has impressed not only its customers but also an array of

industry experts. First, it made history by being the first commercial vehicle to receive the Automotive Researchers and Journalists Conference’s “Car of the Year Special Award 2013.” This was followed in Ireland by the accolade of “Best Energy Efficient Product Award” being bestowed on this impressive vehicle. Steeped in a rich 52-yearold heritage associated with reliability and performance, the new Canter Lift continues to apply FUSO’s long-standing global branding to the future of transport technology in South Africa. “The acronym Lift stands for Light-Duty International Future Truck and this is indicative of our pioneering spirit of always moving forward for our customers and society. As we continuously refine the Canter so that it remains at the forefront of the truck industry, we ensure that we do this with all our stakeholders,” said Godfrey Hani, Divisional Manager for FUSO. Whether the new Canter Lift will be utilised in, refrigerated delivery, bakery applications, butchery, general distribution, courier logistics or any other operation, this vehicle has been designed to provide tailor-made soluEnquiry No: 49 tions.

October / November 2014

KZN Industrial & Business News

materials handling, bulk handling & logistics

On the rise

ince becoming part of Renttech South Africa in 2011, Kelmeg Lifting Services (KLS) has enjoyed a strong growth trajectory, with manufacturing output increasing by 40%. This is according to Rodney Young, Factory Manager at KLS (pictured), who was appointed at the time of the acquisition by Renttech SA. “The growth that KLS has seen in the last two years may be attributed to a decision we made to first invest in our existing equipment and machinery before introducing any new products. We therefore tested, developed and improved our existing infrastructure and product line, and this has paid off with a substantial growth in the company,” says Young. Established in 1991, KLS manufactures a range of quality lifting accessories which include polyester slings, web slings, endless round polyester slings and cargo securing straps. Under the brand name Unilift, the company is well represented in the construction, power generation, petrochemical, paper and pulp, engineering, marine, agriculture, transport and mining industries. Rather than focusing on the end-user, however, KLS relies on

Road, Chloorkop, symbolises a powerful South African business success story. Over the last 10 years the company has worked on the integration of the different activities of the business into a cohesive customer service machine. Since 1984 the Imperial group’s Goscor Lift Truck Company has offered state-of-the-art equipment and solutions to the warehouse and general materials handling industry. Its famous brands – including Crown, Doosan, Bendi and Hubtex and its extensive Southern African footprint of

ndustrial automation specialist, Omron recently announced the E3S-DB, a transparent-object sensor specifically designed for the food and beverage industry. It offers better detection of objects such as glass bottles, PET bottles, transparent trays or packaging film. The E3S-DB represents a new benchmark in industrial sensors for transparent object detection. A high sensing stability makes this new sensor ideal for detecting all kinds of transparent objects found in today’s food and beverage packaging processes. To enable high-precision detection and positioning on conveyors where the smallest of gaps between bottles exists, the E3S-DB is also available in narrow-beam models with convergent beams that have a focused spot size of just 2mm at a distance of 200mm. Developed in close conjunction with customers who produce some of the world’s leading branded food and

beverage products, the E3SDB features a unique optical system that enables sensing with low hysteresis and high dynamic range. This results in outstanding performance. For instance, the E3S-DB is capable of detecting just 3% light-intensity attenuation at a distance of up to 4 meters from an object. The advanced optical system of the E3S-DB increases stability performance by completely cutting off even the smallest amounts of stray light that might interfere with glass bottle detection. Known as the bottle-lens-effect, this unwanted magnification of light intensity commonly causes disruption of glass-bottle detection on packaging lines that use less stable sensors. To meet the trend towards the use of thin PET bottles in the beverage industry, E3S-DB applies the technique known as Polarized-Opaquing,

which offers increased detection stability through special polarizing filters for PET objects. A further advanced feature automatically compensates for light-level changes caused by ambient conditions, or contamination. The newly developed ‘Smart Teach’ function, enables setting up the E3SDB both quickly and with minimum effort. Smart Teach simultaneously provides seamless setting of the light-intensity threshold and fast teaching all in one action. To achieve the maximum operating stability, all an operator has to do is manually pre-select the ideal operational threshold level for the given sensing objects. Then, by simply pushing the ‘teach’ button, the sensor automatically adjusts light emission power and sensitivity according to sensing distance and selected threshEnquiry No: 52 old.

Enquiry No: 50

New head office a symbol of success oscor Lift Truck Company’s G (GLTC) magnificent new head office building in Neutron

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I its wide distributor network both in South Africa and further afield, and has built up strong relationships with each of its distributors. Developments in the off-shore oil and gas industry have led to KLS widening its distribution net in other parts of Africa. When KLS’s drive for improvement led to a decision to be audited by a third party, the company chose ISO as its benchmark, and in 2012, the company achieved the ISO 9001:2008 certification. Manufacturing a quality product has always been Kelmeg’s main focus and, according to Young, the company adheres very strictly to the highest possible industry standards. While much of KLS’s focus has been on improving existing products, the company has also brought new products to market, which, says Young, represent “new ideas based on existing concepts.”

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October / November 2014

KZN Industrial & Business News

PLASTICS & RUBBER

Cost-effective plastic packaging for dairy industry

R10-million investment by Mpact in its fast-moving consumer goods (FMCG) plastics plant in Pinetown in KwaZuluNatal will enable the Group to produce a new type of packaging, especially for the dairy industry. Mpact is a JSE-listed plastic and paper packaging manufacturer.

The new machinery will offer dairy producers high quality plastic containers of varying sizes for products such as yoghurt. The new equipment is already producing containers for an export customer. Neelin Naidoo, managing director of Mpact’s Plastics division, says producers in the dairy sector have made it clear in recent times that they are looking for innovative ways to contain costs. “We are therefore pleased to be able to introduce new machinery that will produce high quality packaging at a high speed. This will help food producers to contain costs associated with packaging,” says Naidoo.

Naidoo says the new Engel 280-ton highspeed moulding machine, together with a label robot will ensure top quality output of a 150ml In Mould Labelled (IML) yoghurt cup, to start with. Other sizes are to follow and will depend on market demand. The machine has an eight-cavity mould operating at a four second cycle time, producing 55 million cups a year. The equipment complies with European safety standards and can accommodate moulds with higher cavitation. The capabilities of the machinery have been tested and proven, says Paul Visagie, general manager of the Pinetown plant. “Four cameras measure each cup ejected from the mould for

defects such as label displacement, label overmoulding and rim accuracy. Small print and multiple colours can also be used on labels without compromising the quality. Specialised IML labels with benefits such as temperature regulation and O2 barriers are also available. Various substrates and thicknesses offer a variety of visual effects ranging from a foiled look to pearlised, matt, gloss and metallic finishes. “By keeping the more expensive elements of packaging consistent, one can differentiate brands within the same category by means of a simple label change,” says Visagie. Enquiry No: 53

Laser – the future of marking in plastics

lastics have come a long way since Alexander Parkes publicly demonstrated this new material called Parkesine in 1862. So too, have the manufacturing processes for this durable substrate. Today, plastic is, due to its ease of use, commonly used for packaging, automotive components, electronic devices, household good, cables, and much more. With the increased use of plastics, comes an increased need to mark, track and trace these products. For years now, technology has leaned towards inkjet marking for fast and effective product identification in the plastics industry. This technology is still widely used , and whilst

it remains the first choice for many, it is till reliant on the constant purchase of consumables, solvents, and inks to make it work. In recent years, growing environmental concerns and a desire to cut carbon footprint has however prompted a need for cleaner marking and identification technology. In answer to this growing need, laser technology, initially invented in 1957, has been improved to accommodate the speeds of fast moving lines in the plastics industry. Furthermore, laser technology is becoming

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just as flexible as inkjet in the range of materials that it can mark onto, with the added advantage of the mark being permanent. Lasers can mark at very high speeds onto metals, glass, plastics, papers,cardboards, woods and much more. What’s more, with the mark being instantaneous, it does not require any drying time, and cannot be smudged, or misshaped which is a common problem with inkjet marking. Traceability Solutions are at the forefront of this technology, and have recently introduced

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Enquiry No: 54

Rubber recycling

he Recycling and Economic Development Initiative of South Africa (REDISA) Waste Tyre Management Plan defines a unique approach to waste stream management that is a world first, making the local tyre industry a national and world leader in recycling. REDISA estimates that there are 60 million waste tyres lying in stockpiles countrywide, many of which are illegal and unsafe or simply dumped in the veld. Almost 11 million are added to this number every year, and for the better part of a century, no one has been held accountable for this rapidly growing problem. Established little over a year ago, the primary focus of REDISA is to build a viable and sustainable new tyre recycling industry, with a core focus on developing job creation and economic opportunities while eradicating harmful waste. The purpose of this plan is to uplift individuals from previously disadvantaged backgrounds. The vision is to create 10 000 new jobs by 2017. As at the end of August, 1424 jobs have been created. In terms of the initiative, tyre producers are

electro-mechanical/electronic

a laser which is capable of marking at line speeds of up to 120 meters per minute. With the recently developed Green Laser technology, which is exclusively available in South Africa from Traceability Solution, the capabilities to mark even difficult plastic components is made easy. These types of lasers are easily integrated into production lines, and, not requiring any consumables, is a much more costs affective solution for companies with high production volumes. The company also supplies and supports a wide range of other technologies, including inkjet systems, hot foil presses, branding irons, dot peen systems and much more.

charged a waste management fee of R2.30 + VAT on every kilogram of new tyre rubber produced. The funds collected are then utilised to develop and support the collectors, storage depots, recyclers, and secondary industries that make products from recycler output. As of the end of September this year, 35 489 tons of waste tyres had been collected and diverted from landfills countrywide. KwaZulu-Natal came in a close second to Gauteng, with the province being responsible for the collection of 7 595 tons when compared to the 9 303 tons collected in Gauteng. In addition to this, 1 503 jobs were created and 23 depots were up and running nationally. KwaZulu-Natal had depots in Pietermaritzburg, Ladysmith, Jacobs and Clairwood. In addition, 83 SMME transporter operations are operating as waste tyre collectors from the 1292 REDISA dealers and the plan is that as the five year rollout continues, more dealers and collection points will be established nationwide. For further information on REDISA please Enquiry No: 55 contact info@redisa.org.za

Mill liner optimisation

f not designed, monitored and managed correctly and timeously, mill liner wear can result in expensive equipment failure and inferior grind quality, which will have a negative ripple effect on the operation of mills. Multotec Rubber ensures that liner design is optimal for the life of the liners and performs condition monitoring on installed liners to ensure maximised uptime by facilitating proactive maintenance. The liner optimisation system comprises a number of elements including MillTraj modelling design software as well as Mill Liner Scanner and Hawkeye to perform condition monitoring for a complete and efficient way of managing mill liners. MillTraj is a software package used to optimise liner design by assessing the impact of varying operational and design parameters on mill charge trajectory to achieve the most effective grind. The Mill Liner Scanner is a laser measuring device that provides Multotec with the ability to perform quick and accurate profile measurements using a more cost effective solution than other traditional mill scanning

systems. This system is currently undergoing developmental testing and will be launched to the market during the course of 2015. Hawkeye converts readings from a Mill Liner Scanner into easy to understand graphical displays of liner wear. Acquiring a pre-emptive understanding of the dynamics involved in mill liner wear gains valuable ground and provides a distinct market advantage for organisations driven by maximised uptime. During the life of the lifters the rate at which they wear increases due to greater slippage of the charge and this means that straight-line tonnage or time based predictions of the liner change-outs can result in unscheduled stoppages due to liner failure. By being able to proactively and predictively determine liner wear based on recorded tonnage, Multotec is able to replace customer Enquiry No: 56 liners before failure occurs.

October / November 2014

KZN Industrial & Business News

CHEMICAL & ALLIED INDUSTRIES

Onshore CIP test rig

eolia Water Technologies South Africa was recently contracted to supply Veolia subsidiary Westgarth with a CIP (cleanin-place) test rig in Angola. The rig will enhance the company’s valueadding services through the provision of an on-shore training facility, allowing a hands-on training experience

for Westgarth’s operators and technicians. This is aligned with Westgarth’s global drive to become a full service provider to the offshore oil market. The test rig is also capable of demonstrating the effectiveness of Veolia’s range of SRO (seawater reverse osmosis) antiscalants, SRO biocides and CIP chemicals when treating sea

and brackish water. In addition, the rig offers clients the opportunity to clean membranes locally on a small scale as well as highlight the capabilities of the group. Veolia Water Technologies South Africa was awarded the contract due to its long-standing relationship with its subsidiary, its in-house manufacturing capabilities, proximity to Angola as well as its vast knowledge of African water demands. “The main purpose of having a test rig is to allow off-line training of operators while also enabling testing of cleaning chemicals and cleaning regimes on membranes. This is because the risk of trial-running different cleaning products on an offshore rig system in full-scale production is too great; possibly jeopardising the entire operation,” explains Warrick Sanders, Project Engineer, Veolia

Water Technologies South Africa. “With this test rig, the trial work can be conducted under controlled conditions on membranes extracted from production facilities.” In addition, Veolia supplied two primary chemicals to be used on the test rig: the Hydrex 4514, an alkaline-based cleaning agent, and the Hydrex 4503, an acidbased cleaning agent. “The test rigs have small offtakes of chemicals and will, in the future, use no more than a few tons per annum. The focus for the installation

was on the supply of the biological chemicals, Hydrex 4202 DBNPA 20% solution, which we have sourced through our partnership with DOW International,” Hein van Niekerk, GM, Hydrex & Consumables, Veolia Water Technologies South Africa, explains. To date Veolia has sold over 18 tons of the Hydrex 4202 biological chemicals to a prominent offshore oil drilling company for testing purposes, with an expected sale of 80 tons annually. Enquiry No: 57

Sole distributor appointment

eter Systems, a division of Set Point Group, with a local branch in existence and growing since 2009 in Westmead, is proud to announce that they are now a sole agency for selling and repairing Silea Liquid Transfer srl equipment in South Africa. “We have been distributing Silea products since 1987 and the exclusive distribution status will give us a competitive edge and further position us as leading suppliers of petroleum products in South Africa,” says Warren Erasmus, MD Meter Systems. Silea SR is recognised as a leading European manufacturer of equipment for handling, measuring, transfer and storage of petroleum products, hot

and cold liquids, compressed gases (LPG), chemical products and industrial applications. “We are very pleased to be associated with a brand that is ISO 9001 certified and entirely controlled by rules and procedures that define the quality standards,” says Erasmus.

The company can provide: loading arms for oil with vapour recovery systems, valves, fittings and components of security, loading arms for the transfer of fuel, LPG and hydrocarbons, loading arms for the chemical and food industry, equipment for tank trucks and rail cars, floating booms, scale manual and pneumatic for shelters and displacement pumps, pump sets and marine brewing groups. Meter Systems specialises in supplying equipment suited for petrochemical, mining, lubrication, garage equipment, agriculture, heavy duty industry, processing for transportation and logistics industries. Enquiry No: 58

Waterproofing Durban sewage pump station

ue to the recent upgrading of the Durban Point Precinct, near Durban Harbour, one of eThekwini Municipality’s sewage pump stations needed to be upgraded and relocated closer to the harbour entrance. Once Group Five Civil Engineers had completed construction of the pump station, Goba Consulting Engineers specified Sika’s specialised products to ensure that the roof area was effectively waterproofed. Firstly, Sikalastic-841 ST, a two-part, elastic, liquid applied pure polyurea membrane with a very fast reactivity and curing time was applied to the roof substrate. This product is applicable in temperatures ranging from -15ºC to 70ºC and is 100% solids with zero VOC. Its excellent crack-bridging properties as well as its chemical and abrasion resistance, makes it the ideal product for many waterproofing and

anticorrosion applications on water tanks, bridges, walkways, parking decks and sewage and waste water treatment plants. Once subcontractor, Industrial Linings Natal, had completed the surface preparations of the roof slab, two coats of Sikafloor-161, an economical, two-part, epoxy resin primer, were

applied. This low viscosity, solventfree, multi-purpose primer is suitable for concrete substrates, cement screeds and epoxy mortars. It is easy to use with short waiting times and provides good penetration and excellent bond strength. To ensure a watertight pump house roof, the entire roof slab (approximately 600m²) including all detailing, was then sprayed with Sikalastic-841 ST (1.5mm thick). The method of coating was achieved using plural component, heated, high pressure, proportioning spray equipment. To complete the new structure an instant grass roof, together with an infiltration system, was installed over the layer of Sikalastic-841 ST. With Durban’s humid, sub-tropical climate and over 1000mm of annual rainfall, the waterproofing efficacy of these Sika products will undoubtedly be Enquiry No: 59 proven.

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October / November 2014

KZN Industrial & Business News

HEATING, COOLING & VENTILATION

The all new oil cooler D urban based company, Mod-U-Flow has grown from strength to strength since the beginning of 2014 with the introduction of a new model range as well as involvement in a number of new projects. The new MF1 or Mighty Flow oil cooler compatible with any oil - from hydraulic, gearbox, transmission, bearings or transformer oil, is also suitable for cooling on plastic injection moulding plants and is readily adaptable for use in any space configuration. It offers high thermal efficiency and a unidirectional flows through shell-pass helical baffles arrangement. The MF1 is manufactured in a range of materials to suit the customer’s requirements. Complete units can be delivered in one day with spare components readily available off the shelf. Maintenance is simple and quick with

the tube pass cleaning done in-situ with no need to remove pipes. The MF1 can also be designed to cool or heat any other type of fluid and is not only restricted to cooling oil. In addition, May 2014 saw the company enter into a project with Elgin Cooling and Tektower, aimed at designing, manufacturing and delivering a unique dual heat exchanger system. This system needed to condense contaminated steam at a temperature of 147°C and then sub cool to 35°C. This was achieved in one modular shell and tube heat exchanger and a Tektower cooling system. There are indications that a larger application is on the cards. Another project - undertaken in February – along with consulting engineers Elliot Breytenbach & Gray – was to design and sup-

ply a Dowtherm oil heater capable of duty of 1130 kW. The heat exchanger, designed by Ray Walker, was then built with components manufactured in their Pinetown workshop. ModU-Flow prides themselves on the fact that the M1and M5 range of modular heat exchangers is 100% South African and designed and manufactured completely in-house.

Enquiry No: 60

Precision gases helping control your emissions

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Managing energy costs in business sustainability

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2012/12/05 11:44 AM

he NERSA-approved hikes in energy costs between 1 April 2013 and 31 March 2018 will represent at least a 47% increase in the electricity costs for businesses over the five year period, with an additional increase due in 2015 following the recent approval of the regulatory clearing account for Eskom. Managing business sustainability on the back of these annual electricity tariff increases along with the current threats to energy security and the fluctuating fuel price is a critical balancing act for South African companies. Despite the considerable potential to reduce operational costs through the more efficient management of energy, many companies are still not proactively identifying opportunities that will immediately enhance energy efficiency. “Many low hanging fruits that would alleviate the pressure of energy price hikes and supply constraints while redirecting the savings back into the business for deployment elsewhere are being left hanging on the tree,” explains Val Geen, Head of Energy at the National Business Initiative (NBI) responsible for the implementation of the Private Sector Energy Efficiency programme (PSEE). In June 2013, the NBI was awarded £8.6-million (more than R150-million) by the UK Government through its Department for International Development (DFID) to implement the PSEE as a countrywide programme of support for energy efficiency improvement in the private sector. The programme is supported by the South African Department of Energy and technical support is provided by the Carbon Trust, leveraging its experience of similar programmes in the UK. The NBI is a voluntary coalition of South African and multinational companies committed to working towards sustainable growth and development in South Africa. The subsidised services offered by the PSEE are aimed at assisting companies of all sizes – from small right through to large entities - to improve energy efficiency, save costs and enhance long-term business competitiveness and sustainability. These services are provided by experienced third-party consultancies with competencies in energy strategy, green buildings, HVAC, pumps, motors, lighting, compressed air and industrial processes, contracted by the PSEE and overseen by a team of professional programme managers and account managers. Achieving greater levels of energy efficiency is a vital driver of business and indeed South Africa’s economy, but it does not need to be a cumbersome or burdensome undertaking. By coming on board with the PSEE, participating companies will have access to subsidised, professional consultants to assist with the establishment of energy consumption baselines, implementation plans, data gathering and benchmarking against global best practices, that will combine to create a sustainable business environment that places energy efficiency at its core, and most crucially, much of which can be achieved without any capital investment upfront. Companies interested in participating in the PSEE programme, receiving more information on energy efficiency or subscribing to the PSEE newsletter are invited to register their interest on the PSEE website www.psee.org. za , call 080 111 3943 or send an enquiry to Enquiry No: 61 info@psee.org.za

October / November 2014

HEATING, COOLING & VENTILATION

KZN Industrial & Business News

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

There is little an operator can do to reduce the flue gas temperature of a given boiler other than keeping the boiler clean. When gas-firing, a reduction of the flue gas temperature of 25°C will improve the thermal efficiency by 1%. In addition, the amount of flue gas generated in the combustion process is determined by the amount of fuel burned and the volume of combustion air consumed. The purpose of the combustion control system of a boiler is to ensure that the right amount of oxygen is available for complete combustion at any given load. Oxygen for combustion is usually supplied in the form of atmospheric air which contains 21% oxygen. By measuring the oxygen content in flue gas leaving the boiler, it is possible to determine the amount of air used. Burners are commissioned by setting up these flue gas oxygen levels to the burner manufacturer’s specifications. Oxygen levels in the flue gas are typically in The GRID What is it?

he main purpose of a boiler is to convert the chemical energy of a fuel into heat energy by means of combustion and then to transfer this heat to steam as efficiently and cost effectively as possible. Gas-fired boiler thermal efficiency is mostly dependant on the waste heat that leaves the boiler via the stack. The amount of heat lost in this exhaust gas is governed by the temperature of this gas, and the amount of flue gas going up the stack. Improvement in thermal efficiency can be achieved by reducing the flue gas temperature, and optimising the amount of combustion air. There is some interplay between these two factors, but generally speaking, the exhaust gas temperature is determined by the boiler designer. This is a function of the installed heating surface and how effectively this area has been arranged by the designer using heat transfer enhancing techniques.

the range of 2 to 4.5%. When gas-firing, a reduction of the flue gas oxygen content by 1% will increase the thermal efficiency by 0.3%, provided combustion is still complete . Most modern control systems are microprocessor based and utilise servo motors to vary the air and fuel inputs to a burner. These combustion controllers incorporate some form of excess air level curve or lookup table to ensure the correct air/fuel ratio is maintained. To cater for variations in ambient air temperature and fuel composition, the flue gas oxygen levels are set slightly higher than ideal, as it is better to have too much oxygen than too little under any firing condition. Insufficient oxygen will result in unreleased chemical energy of partially completed chemical reactions like CO formation. Accurate, repeatable, and safe operation over a wide turndown is possible with such control-

Optimisation of combustion air T

lers and servo motors. To achieve optimum combustion settings, John Thompson Enviropac boilers are supplied with Lamtec combustion controllers as Enquiry No: 62 standard.

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he superior quality and feature-rich characteristics of the reliable Lutian ES and EA Series 2kVA – 6.5 kVA petrol generators from Goscor Power Products offer a reliable and affordable standby or backup power solution for households, farms and small industry. “In a market flooded with cheap, inferior quality, unreliable generators it is refreshing to find a premium brand generator at a competitive price,” says Goscor Power Products MD, Mark Bester. “Purchasing a Lutian is an investment because the unit combines efficient operation and low maintenance to keep the end users’ operational and ownership costs to an absolute minimum.” The Lutian petrol generator comes standard with 100% copper windings, just one of the many features that differentiates the unit, placing it in a league of its own. Aluminium which is the cheaper option most commonly used in generators in this kVA range does not have the excellent electricity conduction properties of copper. The use of copper windings not only improves the Lutian generator’s efficiency but extends the unit’s service life. These generators are manufactured by China Lutian Machinery Co. Ltd. Goscor Power Products, part of Imperial, was appointed as exclusive distributor of the complete range of Lutian products for South Africa and the SADC region. “Lutian has carried over the state-of-theart technology of the Lutian generators to its quality water pumps and high pressure cleaners and since the incorporation of these world-class products into our portfolio in November 2011, we have seen unprecedented success in the southern African market, especially in the agricultural industry.” The Lutian petrol generator range is backed not only by Goscor’s large nationwide dealer network but also enjoys the support of a number of agri-businesses. “We have forged good partnerships with distribution outlets which are our route to market, taking the product to the customers’ doorstep,” explains Bester. “We appointed Irrigation & Pump Supplies & Distribution (IPS) as a distributor of the Lutian ES and EA generator ES and EA Series and the Lutian water pump range 12 months ago. With knowledgeable and experienced representatives, IPS has the necessary infrastructure to deal with agri-businesses and is currently supplying Tuinroete Agri in Eastern Cape, Kaap Agri in Western Cape and NTK (NoordEnquiry No: 63 Transvaal Ko-op) in Limpopo.

CUSTOMER FOCUSSED

High on power, light on the pocket

October / November 2014

HEATING, COOLING & VENTILATION

KZN Industrial & Business News

Convenience through versatility

tlas Copco’s range of small heatless desiccant dryers offer an array of advantages that makes CD2-5 range particularly suitable for point of use and OEM applications. The CD2-5 dryers, available from 2 l/s (4 cfm) to 5 l/s (11 cfm) offer high installation flexibility, have a very small footprint, utilise desiccant cartridges that include an integrated dust filter, and come equipped with an electronic controller with the possibility for remote monitoring. “Installation versatility is a key requirement for units of this size,” explain Charl Ackerman, Atlas Copco South Africa Business Line Manager Industrial Air Division. “The fact that the unit can be installed both horizontally as well as vertically presents a significant benefit. In addition, the multi-port inlet, outlet and integrated after-filtration ensure that the package is a highly attractive proposition, especially when space is at a premium.” The unit is run via an electronic timer

he Mitech steam conditioning valve is a modular system which can contain a combination of Cavitation Control, ZZ or Twister trims and diffuser elements, combined with a steam atomising desuperheater nozzle. The design incorporates an angle-style body which allows for substantial differences in inlet and outlet, both in terms of size and pressure rating. It is also primarily designed to incorporate the well-proven Mitech Twister trim, flowing from the inside outwards for

Fax: +27 31 701 8216

Email: reception@natalpumps.co.za Website: www.natalpumps.co.za

maximum efficiency of space utilisation. The body is further designed to have a large annulus around the stack, such that even relatively high trim exit velocities cannot cause significant erosion damage to the body. However, the plug configuration is such as to give the best possible shutoff with the smallest possible actuator. Furthermore, the plug is guided by the trim, and the trim and plug are designed to have a relatively long stroke, thereby maximising the turndown of the system. The desuperheater nozzle is fitted to the centre of the valve outlet in an area of highly turbulent flow, to minimize the risk of water impinging on

or replace the arresters, while considering safety limits. The SA 30i is designed to work under the hostile electrostatic noise found in live EHV switch yards. A special low-noise clamp-on CT is used to read leakage current in the earthing conductor of the Arrester. The field probe is a non-contact, remote sensing device employed to take the reference signal from the HV line to the Arrester, for measurement of phase and system harmonics. The SA 30i measures 3rd harmonic resistive and total leakage current by compensating the harmonics present in the system as per IEC 60099-5 B2 or without system harmonic compen-

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Enquiry No: 64

either the valve body or downstream pipework. The moment the valve is cracked open, steam is introduced to the desuperheater nozzle at full upstream pressure, in order to maximise the atomization of the cooling water. The water supply to the desuperheater is arranged in such a way that the valve body is not in contact with the cooling water, thereby removing the risk of thermal cracking caused by severe temperature gradient, which is the Achilles heel of most steam conditioning systems. In fact the only component that is simultaneously in contact with both water and steam is the desuperheater Enquiry No: 65 nozzle itself.

Preventative maintenance strategy

est Instruments Africa (TIA) recently announced the launch of the SA 30i, a leakage current meter from Scope. It’s a ‘state-of-theart’, on-line test system for Residual Life Assessment of Surge Arresters. The instrument measures and directly displays the values of resistive and total leakage current. The SA 30i can be pre-loaded with the identity (Asset number, make, year, Serial number etc.) and tests conducted on that same ID are saved in an individual folder. Trend analysis software, Sadata, picks up this data and files it in a similar fashion on a PC. This analysis software enables the user to take a decision to repair

Toshiba C50-B0467

ments of a compressed air system i.e. filters, dryers, etc., backed by a global aftermarket support structure, ensures that Atlas Copco remains first in mind, first in choice,” concludes Ackerman.

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sation as per IEC 60099-5 B1 Scope is a pioneer in developing portable Testing & Measuring instruments for power sector in India and specialises in offering measuring solutions for users as well as manufacturers of power generation, transmission and distribution equipEnquiry No: 66 ment.

SSTech, can now supply a platinum temperature sensor sourced from Jumo in Germany with pre-tinned connection wires to ensure reliable soldering. The PCA ET is perfect for applications ranging from the medical field to heating and air-conditioning technology. In humid environments, it is possible to install this sensor in combined humidity and temperature measuring transducers. Platinum temperature sensors are regarded as robust, long lasting and are characterized by good vibration resistance and fast response qualities. They can also record in high temperature ranges of several hundred degrees. In some instances however, the soldering of the nickel connection wires for the sensors can prove problematic. Jumo temperature sensors had previously only been available without tinning as usually a soldering process is qualified by the end user where the exact flux is specified. By pretinning, any soldering process, irrespective of the used flux, can be applied. The Jumo PCA ET is available in sizes of 1.5 x 5 x 1 mm and 2 x 5 x 1.3 mm. The temperature sensor is supplied with rated values Pt100 and Pt1000 with tolerances of F0.1, F0.15 and F0.3. A special feature is the version in the F0.6 tolerance class which is supplied “on tape” and is suitable for automatic mounting. As a result, this sensor can be applied very ecoEnquiry No: 67 nomically and efficiently.

VSquared Marketing V2/12122 Oct 2014

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controller, which provides the possibility of remote monitoring and purge cycle pause (via a remote signal) as standard. “On top of this, all units are shipped with a series of interchangeable purge nozzles in order for the most optimum performance which can be obtained across a wide variety of operating conditions,” adds Ackerman. Reliable operation and performance is achieved through the use of proven working principals and quality components of the Atlas Copco heatless dryers. The high strength aluminium profiles are anodised to prevent corrosion; the molecular sieve desiccant ensures a reliable pressure dew point down to a minimum of –70°C (-100°F). The smaller CD2-5 dryers complement the larger range of Atlas Copco dryers which comprises 17 different models. It is a clear ambition of Atlas Copco to be able to provide every customer with a complete compressed air solution, not simply an air compressor. ”Extending the offer to include all ele-

October / November 2014

KZN Industrial & Business News

the 9190A specifications for accuracy, stability, axial (vertical) uniformity, radial (well-to-well) uniformity, loading, and hysteresis have been thoroughly and carefully defined and tested. It has a wide temperature range (-95ºC to 140ºC) to cover the coldest and warmest temperatures required in pharmaceutical, biomedical and food processing applications, operating at ultracold temperatures not typically available with a calibration bath. The 9190A uses no bath fluids, keeping clean rooms clean, making

it easier to transport, and delivering faster heating/cooling rates. It offers best-in-class temperature stability (plus-or-minus 0.015ºC) for consistent, accurate results. The 9190A with “process” option features 4-20 mA connectors, a reference thermometer input, 4-wire PRT/RTD input with an accuracy of plus-or-minus 0.02ºC, and a reference sensor control to minimize the effects of the axial gradient when a reference PRT is aligned with short sensors. Enquiry No: 68

Steaming its way to success

and-Air, part of the Atlas Copco Group, has introduced an innovative and economical steam boiler to local industry. The new boiler is a 20 foot containerised unit capable of delivering an output of 6.2 million BTU per hour (approximately 2 720kg per hour) at a temperature of 100°C and a working pressure of 10.3 bar. Steam boilers - large vessels containing water - transfer heat from a fuel source (oil, gas or coal) into steam, which is then piped to a point where it can be used in a variety of applications, including running production equipment, sterilising and steam cleaning. “Steam boilers are very economical. They are also much more costefficient to hire,” says Craig Swart, Fleet Manager at Rand-Air. The new steam boiler, the latest

new addition to Rand-Air’s rental stable, is well testing in the onand offshore oil and gas industry (in effluent heating). It also has an application in a number of other industrial processes, including effluent steam injection; mud transfer; chemical heating; steam cleaning; sterilisation (autoclave and hospitals), heating (domestic and industrial); batch cooking for mass production; spirit distillation; tyre and moulding production, and process heating in the refinery industry. “The unit is packaged in a DNVcertified container, complying with international offshore standards,” says Swart. “It offers ease of use and

accessibility as all operator controls are externally mounted, as well as improved autonomy through connection of an auxiliary fuel tank. Its many safety features include alarm warnings, a pressure safety relief valve, an apex gas detector, an inbuilt CO2 extinguishing system, among others, ensuring the highest safety levels and operational efficiency.” Steam boilers have been used with success at a number of well testing sites in the offshore African oil and gas industry, specifically in the heating of Enquiry No: 69 well effluents.

New compact, flexible infrared camera

nstrotech, local distributor of process control instrumentation and specialised systems, has announced the availability of the Optris PI camera featuring online thermal imaging systems, claiming impressive cost-to-performance ratios. Developed to thermally determine objects and automatically detect hot or cold spots, typical applications are research and development (R&D); test stations (T&M); process automation and portable measurement tasks. The Optris PI covers a range of temperature measurements between -20°C and 1500°C. The camera, once connected to a PC with USB 2.0, can be used immediately after connection. The Optris PI Connect software displays the captured temperature data as a thermal image, while remotely controlling the camera. Based on a small, uncooled bolometer (UFPA) with 160x120 pixels or 382x288 pixels, the Optris PI delivers thermal images in real time with a frequency of up to 128 Hz. Fast processes can be captured and stored as snapshots or video sequences and it’s possible to detect the smallest temperature differences of an object due to the unit’s high thermal sensitivity range.

Staying switched on

Ultra-cool field metrology well delivers stability

he Comtest Group, Fluke’s authorised test and measurement distributor for southern Africa, has introduced the 9190A Ultra-Cool Field Metrology Well, a small, lightweight, and accurate dryblock calibrator with best-in-class stability. The 9190A is ideal for pharmaceutical, biomedical and food processing applications that demand strict quality control and regulatory process compliance, including on-location validation and calibration of RTDs, thermocouples, thermometers, and other temperature sensors. The 9190A conforms to Euramet cg-13 guidelines for best measurement practices for temperature dryblock calibrators. This ensures that

HEATING, COOLING & VENTILATION

egrand’s Arteor range - includes fan controllers, thermostats, electric roller blinds and shutter controllers, as well as curtain switches. Two module fan controllers are available as a four position AC speed control switch, a rotary speed controller for progressive speed control of a ceiling fan, or a 100W fan step regulator. Electronic room thermostats, for controlled heated ceilings and underfloor heating, have a control knob with index and adjustable segments for minimum and maximum temperature settings, between 5°C and 30°C. The Arteor thermostat for electric floor heating has an adjustable setting range between Enquiry No: 71 10°C and 60°C.

Optris PI200 using bi-spectral technology, can combine a visual image (VIS) with a thermal image (IR) which can be captured time-synchronously. In a ready-to-use mode, the cameras’ weight is not more than 320 grams, including lens and cable, making it the smallest (dimensions: 46 mm x 56 mm x 90 mm) thermal imager in the world. And in combination with a tablet PC, the cameras are used

as a mobile solution for preventive maintenance or construction thermography, covering the existing gap between portable infrared snapshot cameras and pure fixed devices. The Optris PI thermal imager’s housing is rated IP 67 (NeMA4) protection class and can be installed in surroundings with temperatures up to 50°C. For applications of up to 100°C, the Optris PI, together with an air cooling system like the Vortex cooler’s air purge collar, protects the lens Enquiry No: 70 from dirt.

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

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October / November 2014

KZN Industrial & Business News

GREEN INDUSTRIES & RENEWABLE ENERGY

Energy saving initiatives reduces energy intensity A

friSam’s campaign to achieve exponential energy savings has led to the implementation of a series of focused initiatives that have resulted in the company reducing its energy intensity by 12%, well in advance

of the National Energy Efficiency Strategy’s 2015 deadline to achieve this target as part of a countrywide initiative. The main success factor has been the introduction of the company’s Advanced Composite Cements,

which harness by-products from the steel manufacturing and coal-fired power station industries, together with chemical activators, to improve the characteristics and performance of traditional Portland cement. Besides lowering the clinker factor, Advanced Composite Cements only utilise half the amount of thermal energy of conventional cements. AfriSam’s “Project Green Cement” was launched in 2000, primarily aimed at reducing carbon dioxide emissions, and since then the company has moved away from the pure Cem 1 Portland cements to embrace Advanced Composite Cements. Today energy is AfriSam’s number one cost reduction initiative and the company has adopted a holistic approach to energy savings to ensure steady improvements in the four primary focus areas of thermal, electrical, transport and explosives. Coal and electrical energy are by far the company’s biggest costs in cement production, with the fuel costs associated with transport logistics a not-too-distant third. “To reduce our electricity usage,

we’ve adopted a philosophy that all our future mills will incorporate electrically efficient vertical roller mill technology,” Gavin Venter, manager of AfriSam’s Strategic Projects, says. “A notable success in this area was the installation of a vertical roller mill at our Roodepoort operation in 2008. Although this mill was commissioned at a 20% higher cost than conventional technology, it has since achieved a 24% reduction in electrical energy consumption. Vertical roller mills are also being earmarked for installation at our new Saldanha and Coega facilities.” “Some time ago we tasked a team of engineers with obtaining maximum

Enquiry No: 72

Green buildings becoming non-negotiable

nother Hollywood inspired technology feature has become a day-to-day reality in today’s construction industry. Buildings controlled by sensors, managed at the touch of a button or even remotely, used to be regarded by movie audiences as amazing science fiction. Today’s offerings of power technologies, control systems and energy efficient applications are becoming a standard feature for new buildings as well as for buildings to be refurbished. Investing in green buildings is no longer a luxury reserved for the select few. Most governments around the world have committed their countries to the stringent environmental requirements of the Kyoto Protocol. While these governments, including the government of South Africa, own that responsibility, the biggest contributors to climate change are by far the industries that are rapidly increas-

ing carbon dioxide emissions. There is thus an expectation that business should step up to the challenge in a much more aggressive manner, demonstrating the inherent will to own and drive the agenda on climate change in the interest of sustainable business. South Africa is still ranked among the world’s most energy intensive nations, but more importantly, the country is also recognised as one of the worst performing in terms of greenhouse gas emissions. This is no surprise, considering that we are talking about an economy where coal is accounting for approximately 75% of primary energy production. With the coal industry experiencing increased pressure worldwide, as it is recognised as one of the driving forces behind climate change and ecological destruction, the South African government is taking active

Mineralised coating technology partnership

energy efficiency out of each plant component and one of the outcomes has been the replacement of old drives with variable speed drives wherever possible, across all our operations. This initiative has certainly contributed to improved energy efficiencies. Where possible high energy utilisation material transport equipment, i.e. pneumatic conveying systems, were changed to mechanical conveying systems. These initiatives required significant Capex expenditure, but could be justified based on the improvement on energy intensity.”

ASF and Smart Planet Technologies are currently discussing a possible strategic partnership concerning the mineralized coating technology, EarthCoating, for paper packaging applications. EarthCoating is a sustainable and cost efficient alternative to traditional extrusion applied coatings providing excellent barrier and heat seal performance and focusing on improving

the recyclability of the packaging. It is engineered for processing within the traditional paper recycling infrastructure and can for example be used for folding cartons, detergent boxes, paper cups, paper plates, etc.. “EarthCoating is a long-awaited breakthrough technology for the packaging industry. A strategic partnership with BASF greatly advances the opportunities for the packaging

steps towards improvements in the country’s energy efficiencies. The Department of Environmental Affairs is leading the way towards a greener economy with its soon to be occupied green head office building in Pretoria. The completely green approach taken in the design and construction of the building, bears testimony to the Department’s commitment to a low-carbon and resource-efficient green economy. ABB Southern Africa is proud to have been part of this milestone project with is many environmentally friendly features, including high efficiency chillers, a tri-generation plant, a thermally shielded and automated façade as well as rainwater harvesting. In addition, the specialised roof structure design and highly glazed façade both help to provide high levels of daylight throughout the buildEnquiry No: 73 ing. industry to leverage EarthCoating towards greater sustainability in packaging applications,” said Will Lorenzi, President of Smart Planet Technologies. “The search for more sustainable coating solutions has been growing in recent years and has become a priority for many companies involved in the paper packaging industry,” added Christian Schulz, Vice President, Center for Sustainable Paper Packaging within BASF. By forming the Center for Sustainable Paper Packaging (CSPP) in 2013 BASF has committed itself to address these industry needs. Enquiry No: 74

October / November 2014

green industries & renewable ENERGY

KZN Industrial & Business News

Stepping stone to low-carbon economy G

as is currently receiving a lot of attention globally, but especially in South Africa, where either gas or nuclear, or both, could replace coal as the main generator of electricity. Dave Collins (pictured), Associate Director of MAC Consulting; maintains that gas might, through emissions reduction, be a stepping stone to a global low-carbon economy and still provide the amount of energy needed to support the world’s nine billion people by 2050. “But,” he cautioned, “this still won’t be enough to fix the global warming problem, bearing in mind that the current trajectory is for around 4°C by 2100 - and 4°C globally means 6-7°C in Southern Africa” He notes that the major published energy forecasts and scenarios were on average suggesting an average absolute increase in demand for fossil fuels of 35% by 2040. Exacerbating the problem is that countries are largely focussing on providing energy security and energy supply right now, with

inadequate responses on emissions reductions from energy consumption in the years or decades to come. Fossil fuels currently contributed 68% of anthropogenic emissions by way of coal (28%), oil (25%) and gas (15%), and 82% of global energy supply, broken down into coal (29%), oil (32%) and gas (21%). While the use of fossil fuels was no more than a blip in the greater scheme of human history, the resultant emissions had been enough to exacerbate climate change. “There is general agreement internationally that a rise in the average global temperature from anthropogenic warming should not exceed 2°C above pre-industrial times if the risk of runaway climate change is to be avoided. So far, there has been little action to prevent this.” Collins says that for many reasons, it will take decades to shift significantly away from fossil fuels. The message of the Intergovernmental Panel on Climate Change (IPCC) had shifted significantly in the past seven years – from documenting dire impacts to finding solutions that integrate with broader societal challenges. “Central to this is positioning climate change in a context of other risks, uncertainties and mega-trends such as poverty and social ine-

quality, urbanisation, and the globalisation of food systems.” The most recent (April 2014) IPCC assessment report is unequivocal about the need to reduce emissions from fossil fuels, although it is positive about using gas in the medium term instead of coal. “The report maintains that GHG emissions from energy supply can be reduced significantly by replacing current world average coalfired power plants with modern, highly efficient natural gas combined-cycle power plants or combined heat and power plants.” He noted that in mitigation scenarios, natural gas power generation without Carbon Dioxide Capture and Storage (CCS) could act as a ‘bridge technology’. However, CCS had not been applied at scale to a large, operational commercial fossil fuel power plant. “CCS-equipped power plants could be seen in the future if they were incentivised by regulation and if the additional investment and operational costs are compensated by sufficiently high carbon prices (or direct financial support). However increasing the cost of fossil fuel energy will of course make renewables more attractive.” Collins said that in order to limit global warming to a certain level, only a certain number of tons of CO2 could be emitted in future. The

Grid-connected PV

nergy costs continue to increase yearon-year, and while the National Energy Regulator has limited electricity price hikes to just 8% over the past few years, this will likely increase in 2015. As a result, electricity is fast becoming a major cost centre for homes and small businesses, leading users to seek alternative energy solutions. Grid-connected Photo-Voltaic (PV) installations offer the ideal solution for the home or Small to Medium Enterprise (SME) consumer, providing a cost-effective solar power generation system that can be used to offset the cost of electricity from the utility provider and reduce the burden on the national grid, says Kevin Norris, Executive Director, Jasco

Power and Energy . Off-grid solutions are connected to a battery, which stores solar energy by charging the battery. These solutions are not connected to utility grids at all, forming completely separate or ‘island’ solutions, ideal for areas where there is no utility power supply. However, in most residential or business installations, this is not an ideal solution, as the battery is often an unnecessary cost, and the purpose of solar energy in these scenarios is to complement utility power during daylight hours, rather than replacing it entirely. Gridconnected PV installations, on the other hand, work together with utility power, providing solar energy when this is available and reverting to

grid-supplied power when it is not. These installations also provide the capability to feed back into the grid, but this is not currently an option in South Africa. A grid-connected PV installation consists of three components: energy generation, power conversion and energy utilisation. Solar cells or solar panels generate electrical energy directly from the light that falls on them. This is direct current (DC), which cannot be used as is in a utility environment. Power conversion therefore must take place

Carbon Tracker Initiative (CTI) had compared this number with the amount of CO2 stored in the reserves of fossil fuels of stock marketlisted companies around the world. In short, the CTI global analysis 2011 concluded that only 20% of the CO2 in the proven global reserves of coal, oil and gas could be released in the period 2011 - 2050 if a 2°C global warming target was to be achieved, which means that governments and global markets are currently treating as assets reserves equivalent to nearly five times the carbon budget for the next 40 years. Investors were hence exposed to the risk of “unburnable carbon”. Finally, he recommended a careful balance among what have been termed the “energy trilemma” by the World Energy Council. These comprise: energy security, incorporating effective management of energy supply from domestic and external sources, reliability of energy infrastructure, and the ability of energy providers to meet current and future demand; energy equity, incorporating accessibility and affordability of energy supply across the population; and environmental sustainability, incorporating supply and demand side energy efficiencies and the development of energy supply from renewable and other low-carbon sources. Enquiry No: 75

whereby DC is converted to alternating current (AC). This task is performed by a Grid Tie Inverter, which includes monitoring and protective devices, and which also regulates the optimal operating mode according to the current solar conditions. Finally, energy utilisation can take place. Grid-connected systems can be used for self-consumption and the excess energy generated can then be fed to the utility grid in two ways, either on a nett metering basis or in the form of a feed in tariff, where you get paid for every kWh of energy supplied back into the national grid. South Africa is currently not set up for twoway metering, on a large scale as a result of complexities with municipal legislation, however this should become available in the near Enquiry No: 76 future.

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green industries & renewable energy

October / November 2014

KZN Industrial & Business News

Fine bubble diffused aeration F ine bubble diffused aeration (FBDA) is internationally recognised as the most energy efficient and environmentally sustainable wastewater treatment system, and involves the generation of millions of small air bubbles that rise from the treatment plant tank floors in order to provide substantial and efficient mass transfer of oxygen to the water. Oxygen is essential in promoting respiration for micro-organisms in wastewater treatment. The oxygen, combined with the sewage food source, allows the bacteria to produce enzymes which help break down the waste so that it can settle in the secondary clarifiers or be filtered by membranes. Pretoria-based EFTEC has been a market leader in the development of FBDA systems since 1999. Municipal and water authorities continue to move from industry-standard surface aeration, which achieves lower oxygen transfer and consumes a substantial amount

of energy, while requiring a larger installation space, when compared to FBDA. “Surface aerator turbines operate on the same concept as a mixer, whereby water is extracted into the air, and a splashing motion creates oxygen transfer into the water. Surface aerators have limitations, as they require larger tanks with depth limitations and numerous support structures,” says EFTEC Managing director Hennie Basson . Basson highlights the fact that large mechanical and electrical installations in terms of cabling and motor control centres adds to costs. “What’s more, the splashing motion releases sewerage aerosols into the air, which is a major health and safety hazard too.” FBDA diffusers – commonly manufactured in tube, disc, plate and dome forms – are evenly spread out in a grid formation on the bottom of the tank floor, thereby ensuring that it is not depth and size restricted. Basson points out

that this provides the plant with improved operational flexibility. “This allows for more precise tracking and supply of Oxygen to satisfy the Oxygen Demand of the Biological Process,” he explains. Depending on the individual variables at each water treatment plant, FBDA technology can result in energy savings of between 40 and 70 percent, compared to surface aerator turbines, which achieve on average 1.8 kg of oxygen per kilowatt hour (kWh) of absorbed power. “FBDA systems generally achieve 0.9 kg of oxygen per kWh per metre of submergence. On a standard 4 m water column, FBDA will achieve 3.6 kg of oxygen per kilowatt hour, which results in energy savings of 50 percent, simply by switching technologies,” he continues. With continued constraints being placed on the national power grid, industries are being

encouraged to adopt more environmentallyfriendly operational practices. In order to keep its FBDA systems as energy efficient as possible, EFTEC makes use of the revolutionary Aerzen Delta Hybrid rotary lobe compressor – an innovative solution that offers the combined features of a positive displacement blower and a screw compressor in one unit. Enquiry No: 77

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he biggest threat to a sustainable water supply in South Africa is not the lack of storage, but rather the contamination of limited available water resources through mining pollution and acid mine drainage (AMD), industrial pollution, wastewater treatment works discharge, raw municipal waste discharge, urban runoff, irrigation return flow and aerial deposition. Multotec has recently launched a water treatment and metals recovery solutions and services division in partnership with Australian company, Clean TeQ. CJ Liebenberg, environmental process engineer at Multotec says that the CIF technology complements the other products and services in Multotec’s portfolio. “Multotec’s core business revolves around the supply of products and services to the mining and mineral beneficiation industries including solid/liquid separation units such as centrifuges and filter presses. Our aim with CIF is to assist in the alleviation of water shortage issues and to encourage sustainable development in South Africa. Mining is often regarded as being a non-sustainable enterprise and we intend to be part of the solution.” CIF is based on the foundation of IX technology, a technology that has been on the market for more than 50 years. It can be likened to continuous sand filtration, the salient differences being that in CIF, charged resins are used as filtration media instead of sand, and in addition to removing suspended solids, CIF also “filters” dissolved salts out of the solution. Clean TeQ has developed three main processes based on CIF . These are single stage CIF for resource recovery and dealkalisation applications, dual stage CIF (DeSALx) for desalination of water and high recovery reverse osmosis (HiROx ), desalination using CIF on the front end of RO to remove scaling, improving the overall performance of RO, and re-using RO brine for resin regeneration for a chemical-free membrane system. All three systems can be adapted to produce a zero liquid discharge (ZLD) process. The main features of CIF include a resin cleaning step to allow the system to operate in the presence of suspended solids, countercurrent flow of aqueous and resin phases for high efficiency ion exchange and that there are minimal moving parts and no complicated internal structures. The plants can be containerised and be fully automated with remote access. These features allow for robustness of the system to treat solutions with high scaling potential. Water recoveries of more than 95% have been realised using this system and production of either agricultural grade or ultra-pure water with TDS concentration less than 50 mg/ℓ is a reality. Enquiry No: 78

October / November 2014

KZN Industrial & Business News

green industries & renewable energy

Dr Rob Davies, Minister of Trade and Industry and Nampak Chief Executive, Andre de Ruyter unveil plaque at Nampak Glass 3rd furnace launch event.

Energy efficient glass furnace opened

ampak’s new energyefficient glass furnace was officially opened recently in Gauteng. The R1,2 billion furnace, which is the third at Nampak Glass, will increase the plant’s capacity to 295 000 tons per annum and create about 140 direct jobs. Nampak has already secured long-term contracts to supply customers with a mix of glass bottles and jars. “Of the R1,2 billion invested in the third furnace, 50% was spent on developing the building in South Africa and the balance was used to buy the furnace equipment in Europe,” said André de Ruyter, CEO of Nampak. The Department of Trade and Industry’s (DTI) section 12I tax allowance incentive on brownfields investment has been a key enabler for the third furnace project. “This is a great example of a truly dynamic public-private partnership” added André. “Currently, the DTI has approved three Nampak Products Limited projects for the 12I tax allowance programme. The total investment value for the three projects is R2 billion. The DTI has committed a total

of R849 million and R12 million on both the investment and the training requirements of the three projects respectively. In upgrading industrial skills Nampak has been awarded accreditation by CHIETA for the L3 Glass Forming Skills Programme. There are currently 12 trainees in the glass making training programme. Nampak has also sent 22 employees for training at the OEM facilities to ensure that they can operate the new equipment,” said Dr Rob Davies. The third furnace is one of the most environmentally friendly and technologically advanced of its kind in the world. Emissions, energy, waste and water are all managed efficiently, with improved flexibility in terms of colour, shape and light-weighting of final products. Specific features include cullet batch preheating from waste gases, a closed-loop water purification system and an ESP filter that reduces emissions. One of South Africa’s largest Rotary Uninterrupted Power Supply (RUPS) has also been installed on the site, removing the risks of power outages and surges.

Green buildings yield financial benefits

new study conducted by Investment Property Databank (IPD) and the Green Building Council of SA (GBCSA) has found that energy efficient (EE) commercial buildings in South Africa deliver better financial returns that non-EE buildings for their owners. This, together with South Africa’s challenging economic climate and the looming 2016 carbon tax system, makes the employment of an EE solution an important investment decision for property and business owners alike. The study investigated 461 commercial buildings and found that the top quartile EE properties delivered a 15.9% total return, 170 basis points higher than the remainder of the buildings which delivered a total return of 14.2%. In addition, while the income returns generated by the two samples of properties were the same, the EE properties achieved a higher capital growth of 8.1%. According to Dawie Kriel, Head of Engineering at Energy Partners,

implementing a holistic EE plan is often simpler than expected and will essentially always yield immediate and sustainable returns on investment. The energy saving potential is dependent on the financial return on investment that the owner would require, he says. “With a long-term investment view, a saving of 50% is quite achievable. There are also innovative financial support instruments available to make the initial investment into EE solutions easier. In most cases the initial interventions could have very little capital investment requirements; we have even seen savings of up to 15% from improved behaviour and corrective maintenance of existing systems. However, this is not guaranteed for any owner, and this is where the understanding of the energy use baseline is an invaluable tool.” Kriel says that transforming an existing building for optimal energy use requires an in-depth understand-

ing of the energy use profile and its components. The results can vary significantly depending on the occupants of the building and the energy requirements, but usually these subcomponents include lighting, climate control, and operational equipment such as IT and data processing, he says. “The information gathered by the measuring process must be evaluated by an experienced energy advisor to identify key saving opportunities.” Kriel says that often the interventions could be as simple as reinstating existing systems to full functionality. “The financial benefit of an effective EE plan is a direct saving on the bottom line that will just increase over time as the cost of energy inevitably increases. The longer owners wait to start the process of managing energy use, the larger the potential losses will become, which can be prevented with the introduction of targeted interventions. ” concludes Kriel. Enquiry No: 81

Optimisation of Combustion Air

Enquiry No: 79

Energy saving lighting installation

agnet has recently completed the installation of an energy efficient lighting system at the new Wolmans luggage outlet at the La Lucia Mall, KwaZulu-Natal. “This project, which involved the installation of modern lighting fittings, has resulted in energy savings of approximately 56 % a month,” says Gary Dawson, sales manager, Magnet’s lighting division. “The design objective was to harness light in the most effective way to create the appropriate ambience in the shop and to show off the true colour appearance of leather and plastic goods.” This installation encompassed the replacement of existing low

brightness recessed (LBR) luminaire technology, with 60 W light emitting diode (LED) panel luminaires. Careful consideration was given to the quality of illuminance levels - an overall improvement of 90% in lux levels was achieved. A colour temperature of 4 000 Kelvin was selected to ensure merchandise is displayed in the most favourable light. Magnet’s understanding of lighting systems, coupled with design and installation services, in-house testing facilities and experienced lighting engineers, ensures enhanced aesthetics and optimum energy efficiency in diverse industries. Enquiry No: 80

Increases boiler efficiency Reduces CO2 emission Reduces fuel consumption

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October / November 2014

KZN Industrial & Business News

COMPANY & PRODUCT NEWS

KZN quarry managers show the way

and and aggregate quarries in KwaZulu-Natal are among the best in the country and show high degrees of compliance with health and safety regulations while simultaneously setting high standards of care for the natural environment. Delegates attending a recent regional meeting of the Aggregate and Sand Producers Association of Southern Africa (Aspasa) at Afrisam’s Newcastle quarry heard that the overall standard of quarries in the province is high and that

the quarry at which the meeting was being held was among the very best run quarries in country. During this year’s strict annual health and safety audits, as well as separate environmental audits, Newcastle was among the best in the country. In addition, ongoing efforts to improve surroundings and make the quarry more attractive were applauded as it adds considerably to the improvement of working conditions. Aspasa regional chairman, Jurgens du Toit, said that the

standard of quarries in South Africa has risen considerably in the past 20 years. “Just two decades ago the average quarry manager was tasked mainly with managing people and machines to break rock. By comparison nowadays, a quarry manager has to be familiar with intense legal compliance matters and needs to be equipped with a substantial “toolbox” of skills in order to efficiently remove minerals from the ground.” “You need to become a specialist in environment protection and you need to be au fait with current health and safety procedures. You also need to have a firm grasp of engineering principals and be able to produce sand and aggregates to ever-stricter specification as required. Perhaps, most importantly, you need to know how to be a good neighbor and be a socially responsible member of the community.” “As a result of this good management the costs of running a quarry are increased and this makes the role of a good quarry manager an exceedingly important one. In KwaZulu Natal we are grateful to have highly experienced and well-motivated manage-

ment teams in our quarries – and it shows,” said Jurgens. He added that Aspasa was an agent on behalf of the industry and plays an important role to assist the industry to understand legislation and implement requirements wherever necessary. The association also works close-

ly with the Department of Mineral Resources (DMR), South African Roads Agency Limited (Sanral) and other key role players to ensure the rules of engagement are fair and that the industry is properly governed. Enquiry No: 81

Bionics in South Africa

Bionic Learning Network team: Frieder Ruhstorfer (Bionics pilot), Dr. Ing, Heinrich Frontzek (Head of Coporate Communication, Festo Ag & Co KG), Markus Schäfer (Bionics Pilot)

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or the first time in South Africa, two revolutionary bionic innovations were recently displayed in Cape Town; the Festo SmartBird and BionicOpter. These were sponsored by Festo Germany for the 19th World Congress of the International Federation of Automatic Control (IFAC) recently held in Cape Town. These innovations form part of the Bionic Learning Network, led by Festo, to take inspiration from nature and create engineered replicas. Dr Heinrich Frontzek, Head of Corporate Communication, from Festo AG & Co. KG was in Cape Town to present at the IFAC congress. “The goal of the network is to motivate, inspire and to kick-start innovation” explains Frontzek. Through his presentation Frontzek demonstrated how using nature as inspiration leads them to more sustainable automation solutions and ways to make it more people-friendly. “Animals have efficient designs for energy and exchange information on where to find food for the advantage of all” says Frontzek, “we try to replicate that with automation for the benefit of all.” The network consists of Festo specialists, universities, students and inventors. Dr Frontzek showed the strides made through various bionic innovations from the Bionic Learning Network, including the two on display at the Congress. With the SmartBird, Festo has managed to replicate the wing motion of a Herring Gull in a robotic form, showing the possibilities for energy efficiency through automated robotics. Taking this initial breakthrough further, in 2013 the Bionic Learning Network presented the BionicOpter, another flying robot based on the dragonfly. Each wing moves independently, allowing it to slow down, accelerate quickly, make sharp turns and fly backwards. The BionicOpter’s motion has been automated to the point that it can be controlled via a smartphone app. Not only are the innovations producing products for industry and inspiration for new developments, the materials used in their production, are similarly at the forefront of technology. Laser sintering was used to generate the prototypes as you can generate a new prototype easily and test it. Furthermore, the polyamide material is very lightweight. “From these bionics, we learn new approaches for automation. More functions integrated into smaller spaces and components are getting smarter” concludes Frontzek. Enquiry No: 82

October / November 2014

KZN Industrial & Business News

COMPANY & PRODUCT NEWS

sHouldn’t you be talking to one of kzn’s largest landlords? With more than a million square metres of lettable space, Ithala’s diverse property portfolio is the second largest in KwaZulu-Natal, following the Provincial Government. With 22 retail centres, 3 industrial estates and 13 light industrial complexes ideal for SMME businesses, Ithala is sure to have the property to meet your unique business requirements. Isn’t it time you spoke to us about your property needs? Tel: 031 907 8792 Email: properties@ithala.co.za

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October / November 2014

COMPANY & PRODUCT NEWS

KZN Industrial & Business News

Is indiginisation the answer to unemployment in SA?

ince the 1960s, indigenisation strategies have been on the agenda for many countries. Thanks to BBBEE legislation, a number of small businesses have benefited from the vital support of various enterprise development programmes in South Africa. However, South Africa has a number of challenges hindering socio-economic growth, and indiginisation of production can become a great contributor towards up-skilling and moving more people into employment. Industries such as transport, manufacturing, construction, energy and mining can benefit significantly from having access to more diversified levels of skills locally.

Yet it is essential that companies in these sectors take it upon themselves to stimulate growth indirectly. One company that has taken a stance to positively contribute to the country’s transformation agenda is the international engineering and energy leader, WorleyParsons. Three years ago the company set up an incubation centre focusing on entrepreneurs in the construction, mining and energy sector. To date each company on the programme has created over 10 jobs during that period. The companies chosen for the programme have been provided with professional office space, personal assistants, bookkeepers, driv-

er services, and even mentorship and coaching. Each company was required to go through a very stringent selection process and effectively demonstrate their entrepreneurial skills. LEAP, a subsidiary of the PLP Group, focuses on design and execution of enterprise and supplier development for corporates like WorleyParsons. Petra Rees (pictured), Head of Business at LEAP, says it’s not only about having a good business model, “The person driving the business is absolutely critical to ensure success in the long run. Until a company turns over R50 mil a year, the business owner is the cornerstone of that

business. Afterwards the company should be sustainable without that individual.” Some of the companies on the enterprise development programme have been executing projects outside of South Africa, demonstrating their high level of service delivery. Other companies are proud to have received local Quality Service Awards from companies like Eskom and Gridbow Engineering. In acknowledgement of the highly specialised work it provides, Gridbow was recently selected as one of Eskom’s elite National Panel of Transmission Substation Contractors. “We received so much from the WorleyParsons ED programme. Now it’s our turn to give back.” says Farai Chabata, owner of Gridbow. His words have translated into the training of a number of apprentices under Gridbow’s Apprenticeship Training Programme. Enquiry No: 83

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in automotive industry

outh Africa’s automotive industry exported more than 30,000 vehicles during September, a substantial improvement over the same month last year. The industry remains one of the economy’s vital sectors, accounting for 11% of exports by value and 6% of GDP. With sustained growth, however, comes the skills squeeze. That’s why Johnson Controls has embarked on empowering young professionals through a graduate development program. “The sector is growing so fast that there are skills shortages at all levels,” says Erna Scheepers, regional HR development manager of Johnson Controls. A global leader in automotive seating, overhead systems, floor consoles, door panels and instrument panels, the company is celebrating 20 years of success in democratic South Africa. During these two decades, it has addressed training and upskilling with a resulting impressive staff loyalty. “In addition to a can-do attitude and ability in manufacturing, we need to develop leadership at management level,” Scheepers adds. “Graduate recruitment is one way for us to bring on board talented, qualified people who are committed to what we do and have the

potential to become the next generation senior leaders of our organization. In addition, this boosts the company in meeting its diversity targets.” Over the last 12 months, the company attracted 20 graduates, the majority female, who were employed at its three operations, Trim and Just-In-Time (JIT) in Uitenhage and Pretoria and Interiors in East London. They were employed on a 12 month contract and assigned a senior employee as mentor to share knowledge, experience and underEnquiry No: 84 standing of the business.

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spray technology is available from Spraying Systems Co. GunJet Catalog 75 provides specific information on hundreds of low-, medium-and highpressure GunJet spray guns that are widely used for cleaning and rinsing applications. In addition to product information, the catalog includes helpful cross-reference tables to simplify matching extensions, adapters and spray tips to spray

guns. Another section is comprised of an extensive list of spare part kits for each GunJet model. Download or request in metric units at www.spray.com. Spraying Systems Co. has the broadest product line in the industry, with several manufacturing facilities and sales offices in more than 90 countries. Spray nozzles, turnkey spray systems, air systems, custom fabrication and research and testing services comprise the 77-year-old company’s offerEnquiry No: 85 ing.

October / November 2014

KZN Industrial & Business News

COMPANY & PRODUCT NEWS

Turning data into imagery

igh-tech computer applications for data management, mapping, modelling and imagery are helping SRK Consulting in KwaZuluNatal to present large amounts of data in a more accessible, visual format – so clients and stakeholders can quickly understand the information and are able to make informed and better project decisions. SRK brings together data from various elements of a project – such as planning, geotechnical, environmental and social – into a geographical information system (GIS) framework to create highly detailed spatial images, according to James Morris, partner and principal civil engineer in SRK’s Durban office. “This allows the information to be communicated more easily within multi-disciplinary project teams and especially to non-technical users,” says Morris. “We have found that the data is far easier to understand and explain when presented in a more visual way – on a local or regional map, for instance. When this information is only in text, tables and graphs in a thick report, it can be very daunting and time-consuming to digest; the significance of key data can also be difficult to extract.” The systems developed by SRK are then integrated with the company’s decision-making tools, so that the improved understanding of selected decision criteria and technical infor-

New power xpert CX in Africa

pretation of geological structures and faults, SRK has completed a catchment-scale assessment in the Amajuba area; this identified areas with high groundwater potential for well-field development, offering a more sustainable water supply and quality. In their presentations to council officials and public representatives, says Kisten, it is useful to show the extensive project-related data on maps rather than just in reports. Enquiry No: 86

Increased demand for forensic investigation

ore and more fraud is being uncovered as companies, employees and even the public sector become more aware of commercial crime. With this comes increased demand for highly specialised forensic investigation skills. Speaking at the re-launch of Santhos Manilall Forensics in new premises, company chief executive, Advocate Santhos Manilall (pictured), said companies were working hard to become more complaint and to put better corporate governance in place. At the same time, employees were becoming more intolerant of dishonesty in the workplace and using whistle blowing lines to anonymously report it.

mation can help decision makers in considering the available options. Non-technical stakeholders may include financial officials, municipal councillors, and a range of interested and affected parties; this method of sharing project plans and details is also beneficial to contractors working on the project itself, who often prefer to see a visual representation of what needs to be done. Working on a rural groundwater supply project in the Amajuba District Municipality of KZN, SRK has also applied high-tech methods while making sure that their findings and recommendations are effectively communicated to clients and affected parties. “In doing an assessment of groundwater resources in rural areas for a local municipality, for instance, we have taken a more regional approach which will optimise sustainability and water quality,” says principal hydrogeologist Raven Kisten. “This is an innovative departure from previous practices, where boreholes have generally been drilled without a full understanding of the area’s water balance or aquifer characteristics.” Using remote sensing and an inter-

The relaunch of Santhos Manilall Forensics comes in the wake of a move to the firm’s new office in Morningside. The company specialises in forensic investigations and disputes, offering a complete spectrum of services, including fraud and anti-corruption investigations, public sector investigations, risk consulting, analytical and forensic technology, business intelligence services, data interrogation and fraud prevention. It comprises a highly skilled multidisciplinary team of 12 with expertise ranging from document analysis to hand writing analysis to advocates and accountants.

For Manilall, greater awareness of commercial crime is not enough - he wants to see more successful prosecutions. He points out that the most disturbing trend of all at present is the increased reporting of procurement fraud that extends from collusion between officials and suppliers to cover quoting. This sees the same company submitting three different quotes for the same contract to manipulate the awarding of large tenders. “Inevitably huge budgets are spent on procurement fraud and people are being unjustly enriched. I’ve investigated cases where people are double invoicing. They are not doing the work properly and then charging double for Enquiry No: 87 that work.”

Lighting solutions partnership

edstone Industrial Suppliers based in Durban is currently partnering with Ellies to roll out a programme for companies who wish to reduce the ever increasing cost of lighting their premises. The programme begins with a full assessment of the company’s current technology and then submits various suggestions for either upgrading or replacing the current system with new energy saving equipment. These new lighting solutions are intended not only to optimize lighting, but are also geared to reducing electricity bills. This new project offers a free audit as part of the programme to assist the making of informed decisions and a saving of up to 70% on lighting bills

can be expected as a result. Redstone is working with lighting design software companies, Dialux and Relux to provide clients with real time light scenes based on actual floor plans, 3D furniture and luminaries to create the holistic effect. In fact this partnership can work magic in any space, be it upgrading and improving warehouse lighting, lighting for a retail outlet or an office or a hotel lobby, restaurant or any other hospitality space. Outdoor lighting is also no challenge to Redstone. In addition, Redstone Industrial Suppliers also caters to various other sectors of the industrial and public markets, offering a diverse range of products, services and solutions for

warehouses, offices, factories and private buyers. The company also assists with storage projects, storage solutions, shelving installations, relocations and refurbishments of shelving systems. As part of their vast range of services, Redstone also supply materials handling equipment such as stackers, pallet jacks, lifting tables, drum handling equipment, paper roll handling equipment, forklifts, chain blocks and crawls as well as a mixed range of floor cleaning machines, cleaning products and cleaning chemicals. A courier network also allows for both national and international deliveries. Enquiry No: 88

ower management company Eaton has announced the launch of the Power Xpert CX, their latest IEC low voltage power assembly with ratings to 5,500 A in Africa. This complete range provides customised power distribution and motor control functionality for all commercial and industrial applications for customers in Africa. The CX is a flexible, modular distribution centre that is manufactured to customer requirements. The CX’s flexibility means that minimal footprint systems can be built using approaches such as multiple busbar configurations, quad-stacked air circuit breaker (ACB) sections, integrated distribution and motor control, as well as customisable cubicle shapes and line-ups. This advantage can be critical in applications such as data centres, where maximum space is required for revenue-earning equipment. Optimum flexibility is achieved with multiple possibilities for fixed, plug-in, removable or fully withdrawable functional units, with accessibility for front and rear access. “Eaton has a strong footprint and local expertise to meet customer needs across Africa, this is complemented by in-depth understanding of local standards, wiring practices and utility requirements”, said Dean Nurden, Product Line Manager for Eaton Africa. “Safety is equally well main-

tained during system maintenance and upgrades, as operators can work under live conditions. In cubicles with a vertical distribution busbar system, screening plates provide segregation from live parts during modification or exchange operations. Easilymanoeuvrable separation plates allow safe changes to compartment layout and sizing”, added Nurden. All customer-specific configurations are fulfilled with consistent high quality and safety, as all are built in Eaton factories using Eaton devices with proven track records and components that meet IEC 60947 and related standards. Complete system safety is ensured and verified by testing according to IEC 61439-2 for low voltage switchgear, which is witnessed by the independent third party authority DEKRA (formerly KEMA). Eaton performs a further set of routine tests in their own global factories and has a thorough quality control regime Enquiry No: 89 in place.

October / November 2014

COMPANY & PRODUCT NEWS

Insulation resistance testers

egger’s new MIT515, MIT525 and M MIT1025 Insulation Resistance Testers are smaller and lighter than previous models yet offer advanced features and rapid charge capability. The range consists of three models; an entry level 5 kV and two fully featured units, one 5 kV the other 10 kV. Resistance measurement is up to 10 TΩ for the 5 kV models and 20 TΩ for the 10 kV model. A key productivity feature is the ability to take measurements when connected to line power/mains with a dead battery. Intelligent battery charging ensures the optimum charge rate as a function of battery level, resulting in minimum charge times. The rugged case provides ultimate protection for a

portable instrument and a clip-on lead pouch ensures that leads remain with the instrument at all times. The case lid is removable for improved terminal access. IP rating is IP65 with the case closed preventing water/dust ingress. High reliability and safety are built in; all models are safety rated to CATIV 600 V and are double insulated. Five preset voltage ranges are provided in insulation test mode, plus a user settable lock voltage range. Preconfigured diagnostic tests include Polarisation Index (PI), Dielectric Absorption Ratio (DAR), dielectric discharge (DD), Stepped Voltage (SV) and ramp test. Simplicity of operation is achieved with two rotary switches and the large backlight display enables multiple results to be displayed simultaneously. Advanced memory storage includes time/ date stamping of results, logging of data and recall of results to screen. Megger is represented locally by Surgetek. Enquiry No: 90

KZN Industrial & Business News

Certification for bearing protection range

abtecta mechanical seals, the patented bearing protection range from Aesseal, are now ATEX certified, complying fully with ATEX directive 94/9/EC. Their compliance makes them the first seals of their type to be certified to the latest harmonised EN standards, allowing installation in environments with potentially explosive atmospheres. ATEX certification is extensively specified in applications throughout South Africa and Europe. Bearing failure accounts for 20,8% of all rotating equipment downtime, with bearing contamination identified as the major cause. The Labtecta mechanical seal reduces the chance of bearing failure by preventing the egress of lubricant and the ingress of water and dirt. It is an advanced non-contacting labyrinth seal with integral shut-off valve. Various models cater for top entry, axial movement,

outboard and inboard air purge, and other extreme requirements. Labtecta’s design uses centrifugal forces to open and close micro-gaps in the seal to ensure that the application can breathe when running, but is perfectly sealed from contamination when stationary and the forces cease. In the steam turbine bearings found in petrochemical refineries, potential savings running into the millions can be achieved by installing Labtecta to eliminate the expensive lubrication interventions required by the fixed labyrinth seals in general use. A refinery typically has a fleet of over 100 general purpose steam turbines. Research indicates that by improving the bearing seal arrangement there is scope for annual savings of in excess of R10-million over seven years.

Enquiry No: 91

Next-generation cleaning diesel

ngen Petroleum, South African fuel brand and market leader, is an ally to financially stretched motorists with an intelligent diesel that offers both fuel economy and the restoration of lost power. Since 2012, Engen Dynamic Diesel (also available in lowsulphur 50ppm) has been giving motorists economy without sacrificing power, says Joe Mahlo, general manager of Engen Sales & Marketing. Dynamic Diesel comes with a multifunctional detergent additive package that delivers excellent clean-up and keep-clean benefits throughout the fuel distribution system, Mahlo explains. It contains a unique combination of deposit control additive chemistries. These counteract injector deposits, nozzle fouling and restores lost power as soon as the fuel is introduced, improving fuel economy and reducing exhaust emissions. The noticeable feeling of better driveability is at its most dramatic in engines that have already suffered diminished performance, he

says. “Within two or three tanks of fuel, Engen Dynamic Diesel begins to restore original design performance.” Like its predecessor, the new fuel also substantially reduces foaming and protects against corrosion. The new reformulated fuels followed on months of market research by Engen into the South African fuel market, says Mahlo. “We’ve found that petrol motorists don’t want to choose between performance and economy, and appreciate the importance of clean engines,” he says. “Diesel motorists want economy above all. Both types of motorist want their fuel to keep up with global technology advances.” Armed with the findings of the research, Engen developed the most advanced additive packs that would satisfy both groups of motorists. “What matters to motorists matters to us,” says Mahlo. “These are tough times, and they’re looking for extra bang for their buck.” Engen was recently named South Africa’s leading fuel brand in the Sunday Times Top Brands Awards for the fourth consecutive year. This comes hot on the heels of the company being named the ‘Coolest Petroleum Brand’ for the fourth successive year in the Sunday Times Generation Next youth survey. Enquiry No: 92

Secure machining of deep internal grooves

he recently introduced CoroCut QD concept for deep external grooving and parting off from Sandvik Coromant, now adds internal machining to the application range of these secure and reliable tools. As from the beginning of October, the CoroCut QD system now includes CoroTurn SL blades for deep grooves in internal machining. The modularity of the CoroTurn SL interface enables tool assemblies to be optimized for the specific application. Internal grooving and parting off with long overhangs require stability and tooling solutions that keep vibration to a minimum.

The stable clamping mechanism on the CoroCut QD tools is now supported by the use of Silent Tools dampened boring bars for vibration-free machining with long overhangs. For tube-shaped components, typically found in the oil and gas industry, this is welcome news enabling deep internal grooving to be machined with high process security. As with the previously introduced CoroCut QD tools, the extended assortment features over- and under coolant. The over coolant takes care of chip control while the under coolant prolongs tool life, together further adding to securing the machining Enquiry No: 93 process.

COMPANY & PRODUCT NEWS

Placing global automotive firm in the driver’s seat

outh African based business technology partner AWM360 Data Systems has supplied its client, a well established international automotive engineering company, with a solution to effectively address a requirement for enhanced SAP-certified integrated time and attendance and access control, nationally. The client is focused on unique systems competence in the combustion engine and engine peripherals. It has a presence in Durban and Port Elizabeth and has a staff compliment of approximately 2000 employees. In line with the global holding company’s strategy regarding its workforce management needs, AWM360’s client looked to the market and a potential partner to provide a scalable solution with hardware that would suit its production environment and its overall global procurement policy in this regard.

The implemented solution is based on the client’s SAP software as well as on Kaba’s server technology and Kaba hardware. AWM360 Data Systems, a solution provider within the Southern African Human Capital Management (HCM) and Workforce Management Solutions markets, is one of only a handful of global Kaba AG reseller partners and Kaba’s partner for Southern Africa. Kaba AG is a long-time certified SAP partner and global manufacturer of access control and enterprise data recording solutions. Kaba AG’s generic solution portfolio incorporates access management, workforce management, physical access systems and specialised lock & key systems (including cylinders). This extensive profile is targeted at businesses of any size, across a variety of sectors (with govern-

ment, enterprise and retail seen as key) and available via the Company’s reseller network. The network incorporates both established representative operational offices and/or support structures to contribute towards the success of projects. Following a thorough consultation process, AWM360 Data Systems supplied Kaba’s B-Web series terminals with biometric readers for time recording. “We chose B-Net 9290 and B-Net 9250 controllers, in combination with B-Net 9105 biometric access control terminals, to cover our client’s access control needs - as well as B-Web 9300 series biometric terminals for all time and attendance needs,” says Guenter Nerlich (pictured), MD, AWM360 Data Systems. “An SAP-certified integration into their global SAP environment and the Kaba B-COMM ERP 4 SAP solution based in Germany was a necessity.”

Evolving MRO market

as couplings, fittings, valves, filters, lubricants, oil, tooling, safety equipment and more. But as important is the knowledge, expertise, information and support that goes hand-in-hand with high product availability. The customer won’t always know exactly what they need, or what is best to solve a specific problem, and so an MRO specialist such as ParkerStore who can also take on the role of trusted advisor is of huge value. Furthermore, the ability, if required, to deliver that expertise at the end customer location is also important. ParkerStore is an example of an organisation that has drawn on its many years of experience at the frontend of the MRO process and recognises the huge importance of helping such mistakes being avoided. Consequently, supplementary initiatives such as the clear identification of components on the part itself and extensive manufacturer cross-reference apps for products such as filters have been developed to minimise risk.

he hydraulic and pneumatic maintenance, repair and overhaul (MRO) requirements of all types and sizes of manufacturing business have changed considerably over the past 20 years. In line with this evolution, the services, products and capabilities that exist to support them have changed too, according to Eric Zany, Channel Manager EMEA, Parker Hannifin. For MRO specialists – companies contracted to provide maintenance and repair parts and services - the past two decades have seen a dynamic shift in business strategy. The end customers being served by these operations cannot afford downtime, as this comes with a heavy price tag in terms of cost, but also with regard to lost productivity and reputation. When plant and equipment needs repair, MRO organisations have to act quicker than ever as production and projects are costed and monitored more tightly today than at any time

before. Products, knowledge, service and reaction time when a product or system goes down on site is key to setting an MRO specialist apart from its competitors and pleasing the end customer. Whether it’s the face-toface service provided by knowledgeable staff, in-store hose make-up and repair capabilities, or on-site hose fabrication such as with Parker’s Hose Doctor and ParkerStore units, the service an end user gets is crucial. MRO specialists such as ParkerStore provide an environment for the immediate and direct sale of industrial products through an approved platform that serves the walk-in MRO customer. Combining the trade counter and retail models, such outlets allow customers to order bespoke, while-you-wait hydraulic hose assemblies while shopping for complementary products such

New lubrication monitor

KF announced the introduction of the GSM (Global System for Mobile Communications) Lubrication Monitor for use with its automatic lubrication systems. Developed to avoid damage caused by improper lubrication, the device monitors system pumps that are not connected to control centers and notifies maintenance personnel of an empty reservoir or another lubrication issue by sending an SMS message to one or more cell phones. Requiring only the device and a cell phone, the GSM lubrication moni-

tor is a cost-effective solution for monitoring lubrication pumps in difficultto-access locations. The lubrication monitor features a pre-configured, plug-and-play design and is easy to install. It is set up using free PC software via a serial port or by cell phone using SMS commands. The low-maintenance GSM lubrication monitor operates continuous-

What lies behind ABB Low Voltage switchgear?

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

Enquiry No: 94

Mobile payment adoption on the increase

HIGH IMPACT TRAFFIC DOORS

GENERAL PURPOSE STRIP CURTAINS WELDING AND SAFETY SCREENS HIGH SPEED ROLL UP AND FOLD UP DOORS

Enquiry No: 95

ly and can be set to automatically provide a status report on a predetermined schedule. Up to 10 phone numbers can be synchronized with the lubrication monitor and can send various SMS commands. Alarm and recovery messages are time stamped for convenience. An optional temperature sensor and internal battery are availa b l e for use with the GSM Lubrication Monitor. Also, this reliable device can be retrofitted to upgrade existing systems. Enquiry No: 96

mall businesses face a way of collecting payments.” number of challenges on “In addition, with the advent their road to becoming sus- of truly intuitive apps, the move tainable enterprises. Not the least towards mobile payments was of these has been the problem of inevitable. Consumers are using accepting card-based payments their phones as tools to enrich for services rendered at customer their lives; almost everything about sites or at venues such as local them is stored on their phones markets, due to the relatively high including their wallets. Businesses cost of point-of-sale (POS) devic- now need to access these vires needed to process sales. tual wallets and one way of doing This however is rapidly becom- that is through SnapScan,” says ing a thing of the past as more Mpako. SnapScan is small businesses are embracing geared to equip small businesses the technology of SnapScan and with a quick, easy, affordable and moving towards mobile payment secure payment solution that is solutions explains Vuyo Mpako, driven by Quick Read (QR) techHead of Innovation and Channel nology. It provides businesses Design at Standard Bank. with cost-effective hardware, in Specifically developed for the this case, software in the form of small business sector by Standard a unique QR code that’s printed Bank, SnapScan has signed up on paper. So instead of turning over 12,000 small businesses customers away due to a lack of nationally, in three short months. a POS system, business owners “As a financial institution serving can now in essence accept cards. thousands of small businesses, The process is really simple in we believed that this was a major that customers scan the unique impediment to the future develop- QR code and confirms the transment and sustainability of small action with their user-selected businesses. There was an urgent PIN. The merchant immediately need to provide a real-time pay- receives confirmation via SMS. Enquiry No: 97 ment solution that offered a secure

A network of agents throughout South Africa ensures excellent technical and installation support, and quick delivery times. Coralynne & Associates +27 (011) 849 3142

October / November 2014

KZN Industrial & Business News

011 452-8723 021 551-5076 KWAZULU-NATAL: 0 8 6 1 0 3 3 3 0 3 PORT ELIZABETH: 041 487-2525 www.apexstrip.co.za JOHANNESBURG: CAPE TOWN:

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

7/18/2014 1:14:46 PM

Hydraulic oil test

October / November 2014

COMPANY & PRODUCT NEWS

ydraulic systems, particularly construction machinery and material handlers, often operate at full capacity: low tank volume, high circulation rates, high pressure and high specific oil levels. As a result, after a period of use, the oil in these systems can often no longer reliably meet the requirements placed upon them. The demand for lower fuel consumption and the associated reduction of CO² emissions, while maintaining the same level of performance, can only be met by using special hydraulic oils such as Renolin Xtreme Temp. Alongside a number of other tests, nine days of field tests lasting several hours were carried out, with a shovel excavator in which the machine was unloaded at 180°, from a distance of 30 meters using Renolin Xtreme

Temp. The work cycle was constantly repeated. Renolin Xtreme Temp 46 was compared with conventional hydraulic oils for this application. At full load, the fuel consumption of the excavator was 20 litres per hour using conventional hydraulic oil. With Renolin Xtreme Temp this figure dropped to just 17 litres per hour – a significant reduction. When used in a track excavator for over 4000 working hours, with a hydraulic system volume of 255 litres, it quickly became apparent that the higher price of Renolin Xtreme Temp 46 is outweighed by numerous advantages, namely the 12% increase in production which makes it possible to move more earth during the same period, or the same time required to move the same amount of the earth was reduced. In addition, the fuel required for the excavator reduced by 12 680 litres – with consumption of 80 017 litres of fuel compared to 92 696 litres when using a conventional hydraulic oil.

Enquiry No: 98

KZN Industrial & Business News

Electronics and control technologies in construction

lectronics and control technologies are becoming increasingly important in construction machinery, which has long been dominated by hydraulic systems. Sensors such as encoders or potentiometers are being used to provide control units with positioning and angular and speed data. This application places high demands on sensors. Outdoor operation is subject to varying climatic conditions such as extreme temperature fluctuations and the ingress of dirt, dust and liquids. The resulting requirements for high ruggedness and a high degree of protection form the basis of Hengstler’s newly

driver in case of any emergency. A classic example is the tilting of hoisting equipment such as cranes and excavators due to excessive loads. Encoders used in construction equipment always prove their capabilities under extremely harsh conditions by providing reliable feedback on the positioning, excursion angles or speeds. The robust encoder families from Hengstler have proven technology that is completely free from sliding contacts and therefore ensures high reliability and longevity. Enquiry No: 99

Hydraulic solutions add precision for iron smelting

osch Rexroth, distributed in southern Africa by the Hytec Group of Companies, was contracted by Wooding Industrial Corporation in Pennsylvania, USA, to supply the hydraulic componentry for a rotating material distributor within a blast furnace for enhanced iron smelting capabilities. “What made this project unique was the stringent specification on accuracy for an application with huge dynamic load changes,” explains Charles Erdo, industrial machinery engineer at Bosch Rexroth in Bethlehem, Pennsylvania, USA. “The control system has to react fast enough to maintain a very tight cylinder stroke tolerance between four differential area hydraulic cylinders.” Bosch Rexroth’s solution, based on hydraulic engineering, commissioning and technology, comprised

designed encoder families, available locally from Countapulse Controls. Encoders are used for positioning, angular, speed and length measurements in construction machinery applications where they facilitate both the driver’s work and enhance productivity, such as straightto-the-point positioning of loads for hoisting equipment or restricting work zones in order to protect against collisions. However, they also allow for the introduction of safety-relevant functions, giving warning signals to the

high-response directional proportional valves, electronic pressure transducers and control software for closed loop control. Metallurgists have consistently sought to revise the centuries-old design of the iron blast furnace, with

contemporary strategies aiming to optimise the composition of charge layers for increased production and efficiency. Sinter and coke layers are created by an internal hydraulic distributor, using a chute located in the throat of the blast furnace to deposit raw materials in precise locations. The more accurately the chute can be controlled, the more precise the layers and the more efficient the blast furnace becomes. Wooding Industrial Corporation’s end user’s existing furnace distributor utilised a traditional hydraulic circuit with open loop control, offering only a limited degree of chute control for the distribution of large quantities of iron ore pellets and coke. Enquiry No: 100

Cold shower for stubborn dirt

ärcher supplies high-pressure cleaners for professional, home and garden use. In agriculture, crafts and trades, industry and municipalities these machines fulfil every cleaning demand wherever large areas must be cleaned daily. The new HD Compact class, including the HD 5/15, is a range of cold water high pressure cleaners designed according to customer requirements in mobility, accessory storage, flexibility and reliability. “When you need to clean machines, vehicles and buildings daily, the use of high pressure and a high flow rate is the best option. Cold water high-pressure cleaners with water flow rates of up to 1,300 l/h remove even stubborn dirt and are ideal for large areas,” says Kärcher sales manager Dean Fairley. “Clients making use of this compact class range from industrial manufacturing businesses, where clean work-

ing areas are essential for safety, to businesses like car dealerships that need to maintain a clean showroom and a clean repair centre. They are also very useful for tradesmen such as plumbers and painters,

when areas need to be cleaned prior to and after work.” Outdoor areas are not only subject to dirt produced in daily work operations, but also to environmental influences. “Dirt in working areas accumulates rapidly. Vehicle deposits, mud, dust and debris after rainstorms are easily removed with high-performance Kärcher machines. For the removal of oily and greasy dirt on large surfaces, we recommend the use of high-pressure cleaners with additional surface cleaners.” The compact class offers fast and thorough cleaning, operating with cold water. “These machines are light and powerful. The all-rounders of the compact class clean up courtyards and workshops quickly and efficiently. They also feature impressive pressures, flow rates and durability,” says Fairley. Enquiry No: 101

Please set your air-con to 23°C and save up to 10% on your electricity bill. Wise usage of air conditioning systems in commercial buildings is one of the most important steps a business can take to keep South Africa powered up during the hot summer season. Less is more this summer.

For more information on air conditioning tips, call 08600 37566 or visit www.eskom.co.za/idm Eskom Holdings SOC Limited Reg No 2002/015527/30

Powering your world

Mohlaleng_2153_E1

October / November 2014

COMPANY & PRODUCT NEWS

KZN Industrial & Business News

Executing safety standards F or more than a decade, KBC Health and Safety has assisted the Centralised Induction Training Committee (CITC) in establishing and maintaining a centralised induction training centre that provides general safety induction training to all contractor employees working on CITC member sites located across Richards Bay. The CITC is comprised of a group of corporate firms that assist member companies by reviewing, recommending and helping with training to create a general standard of service across its members’ various work sites. The partnership was formed in 2002 to improve and standardise all safety training across the board. “KBC works with the individual contractors and companies, while CITC provides an oversight function by means of a service level agreement. The benefit of this association is that a minimum standard has been established across the various indus-

tries in terms of basic safety training,” explains CITC chairman Franz Schmidt. Most CITC members have contractors working across several sites in Richards Bay. “In the past, employees had to first complete general safety training, as well as training to address the respective site specific hazards for each of the sites that they would visit. The training from KBC is recognised across the various sites and eliminates the need for further general safety training on each site.” Having to attend the various site specific safety training sessions resulted in additional costs to corporate clients and contractor companies that had to pay wages for time spent in class. It also prompted the need to provide replacement staff to sites where workers were required to attend the induction training, in order to ensure that there were no stoppages.

“Being able to access sites across industry once the relevant training has been completed reduces the time and cost to get contractors on site for both corporate members and contractors alike. An advantage to the training taking place in large groups is that it can be provided at a more cost effective price too,” adds Schmidt. The training takes place at the KBC Health and Safety Centre in Richards Bay, and covers various aspects of safety. There are also CBT courses offered that deal with legislation requirements according to the Occupational Health and Safety (OHS) Act and the Mining Health and Safety (MHS) Act. The CITC structure is unique and an industry first. KBC has replicated the model in other industries as the benefits to corporates and contracting companies alike have been significant. Enquiry No: 102

Switchgear landscape beyond IEC61439

he control and protection of plant and personnel is of great importance to owners and operators of commercial and industrial facilities across the world. The constant revision of standards and associated legislation, reflecting technological progress, is important for the protection of both equipment and people operating near electrical apparatus. Electrical switchgear, essential to the control of processes in industry, has received attention in the regulatory environment, with a revision to the standards guiding the manufacture of electrical assemblies in South Africa. IEC 61439-1 and IEC 61439-2 standards and their interpretation are the subject of many articles and workplace discussions with little attention to that which follows compliance. The ABB MNS switchgear solution has been subjected to IEC 61439-2 compliance testing by DEKRA and demonstrates full compliance and carries KEMA certification. Additionally, IPH-Berlin has also awarded ABB MNS ASTA certification following a rigorous programme that includes test

laboratory audits by Intertek. This certification provides objective authoritative, written evidence confirming that ABB MNS equipment complies with relevant safety standards and statutory regulatory specifications. Once compliance has been achieved by switchgear manufacturers and panel builders their focus must shift to seeking improvement in switchgear productivity by paying particular attention to plant reliability, availability, maintainability and safety

(RAMS). Low voltage switchgear, particularly motor control centres (MCC), provide the opportunity for engineers to make a meaningful contribution to improved productivity. Issues arise when approaching MCCs from a RAMS perspective. These include; skilled engineering workers are required to determine the corrective actions, as no rootcause failure information is available, absence of early-warning systems alerting operators to potential problems, a shortage of maintenance data, noting what and when work must be undertaken and design of individual starters that require manual adjustment. Central to efficient plant operation from a RAMS perspective is therefore the supply of maintenance information, to the required level, at the appropriate time and the flexibility to perform the required maintenance for the switchgear, in a manner that is safe for both personnel and equipment. Enquiry No: 103

Diaphragm pumps in electroplating application

IA Kunststoffund Galvanotechnik, a leading manufacturer of plastic components with metallic surfaces for the automotive industry, is using Qdos pumps from Watson-Marlow Pumps Group to dose processcritical additives into its electroplating machines. Replacing diaphragm pump technology, Qdos was selected for its precision, reliability and low maintenance costs. Car manufacturers are increasingly demanding metal-plated plastic surfaces. Chrome surfaces for both interiors and exteriors increases prestige considerably, particularly in mid-range and luxury cars. As a result, these chromeplated controls and trims must meet the highest technical and aesthetic requirements. At the headquarters of BIA, the 950-employee company operates a total of four electroplating machines that help produce more than 450,000 metal-plated plastic parts every day. “Our core competence is electroplating, and we have designed our own state-of-the-art electroplating machines,” says Alexander Zabel, Maintenance Manager at BIA.

Each of the company’s four electroplating machines has a dosing station, which is where several dosing pumps introduce important additives into the electroplating baths, such as brighteners, wetting agents and accelerators. “In modern electroplating machines, the question of when, where and in what form additives are dosed plays a crucial role in the quality of the end product,” explains Zabel. “This means that the dosing station is a vital part of the electroplating process.” The highest level of precision is required to ensure the correct concentration of additives in the electroplating baths, and ultimately the quality of the coating on the plastic parts. In addition, of utmost importance is gentle transportation with as little pulsation as possible. Failure to achieve this could mean that the transported additives become “shattered” with the result that they cannot deliver the desired effect in the electrolyte. Until recently, diaphragm pumps were used as standard in the dosing stations at BIA, but they were proving problematic. Not only was there a problem with precision, but a more serious issue was the frequent, time-consuming and costly maintenance incurred by the diaphragm pumps. The company had been looking for alternatives to diaphragm pumps for a long time, and “struck gold” when it found WatsonMarlow. “In May 2013 we decided to test the new Qdos dosing pump,” he says. “We were impressed with the results right from the start. Firstly, Qdos provides 100% precision, the Qdos pump also works without any accessories, such as

seals or check valves, making installation easier. The main advantage of the Qdos pump from Watson-Marlow is the long maintenance intervals, short downtimes and low maintenance costs. Enquiry No: 104

Wound rotor motor protection

esigned specifically to protect wound rotor motors on winches or overhead cranes, NewElec’s 330 Series motor protection relays provide accurate, full RMS load protection and adjustment. Wound rotor motors used in such applications are designed for specific duty classes, starting class, cyclic duration factors, as well as power and load current values. NewElec’s 330M crane motor protection relay is uniquely designed for each motor, providing overload, phase loss and phase unbalance protection. Accurate repeatable protection on small or marginal loads is maintained with a user-selectable maximum load threshold, adjust-

able from 30 to 100% of the CT primary current. Unbalance and phase loss protection utilise a user-selectable detection threshold on a continuous linear scale between 2 to 40% of the maximum motor load current value. The 330 Series calculates true RMS load patterns as well as heating and cooling rates, which ensure that motor loading and CDF are maintained within the tolerable thermal envelope of the motor. LEDs indicate overload threshold and trip, unbalance detection threshold and trip, separate trip indication and the thermal lockout period. Available for either chassis or flush door mounting, the relays’ optional thermal trip state indicator can be mounted as far as a kilometer away from the protection Enquiry No: 105 relay.

October / November 2014

COMPANY & PRODUCT NEWS

Improving water quality

Slim design power supplies

part from the particularly space-saving housing, the new 24V power supply family from ifm electronic is distinguished by a high degree of efficiency. Depending on the version, output voltages range from 3.3 to 20A. In addition, the units possess high power reserves and reliably switch off the circuit breaker in case of a short circuit. Thanks to innovative technologies, the new power supplies require considerably less space in the control cabinet. Another advantage is the above average efficiency of up to 94 per cent.

This reduces waste heat and saves energy costs. Instead of using a NTC resistor, a microprocessor controller keeps the inrush current low, making it easier to protect the wiring. The positioning of the components allows permanent operation even at the limits of the specification. This results in excellent MTBF values ranging from 0.89 to Enquiry No: 106 1.4 million hours.

Steel turning endurance

iva Engineering Projects, a project management company with countrywide capabilities in mechanical, electrical and chemical engineering, is in the process of installing four vertical turbine pumps at the Vaal pump station extracting water for the Mpumalanga towns of Standerton and Sakhile. A fifth pump, this one a single stage centrifugal backwash machine, has been ordered for the water filter plant as a replacement unit. The five pumps were ordered on behalf of Lekwa Municipality from Wadeville-based manufacturer APE Pumps. Together valued at R3,6-million, they will deliver improved efficiencies and longer useful lives for the municipality, achieved through the use of high quality castings and improved machining techniques during manufacture. The four APE model 250VTC48030/1 pumps have stainless steel

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impellers and capacities of 500m³/h at a 30-metre head, while the APE model

18HC single stage machine has a capacity of 720m³/h at a 10-metre head. The 250VTC pumps have been manufactured at APE’s factory abroad and are to be delivered to South Africa on October 23. They will be assembled at the local APE facility for delivery to site by the end of this month, where they will be installed to increase capacity already delivered by two existing APE vertical turbine pumps, replacing four abstraction tower machines that have reached the end of their useful lives. The 18HC single stage pump will replace an identical but earlier version of the same APE pump installed in the western tower some 40 years ago. The improved efficiencies of the new machines will result in improved cost efficiencies for Lekwa Municipality because of a lower power consumption, the Enquiry No: 107 spokesman added.

Expanding keys management systems portfolio

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KZN Industrial & Business News

lobal leader in door opening solutions, ASSA ABLOY, has, over the past 20 years, expanded its world-class product portfolio through numerous acquisitions of premium international brands. The acquisition in 2014 of Traka Africa as a specialist in the security field with a unique and innovative security product portfolio, was an easy and lucrative business decision. Traka Africa (Pty) Ltd was established in 2001 when a need for Key Control in the Sub-Saharan market was identified. “From a choice of several systems, we selected the most superior product and are delighted to be the official Sub-Saharan distributor for the Traka key management system focusing on keying solutions mainly for the mining, engineering and industrial sectors,” comments Quintin Boukan, ASSA ABLOY South

Military establishments, financial and correctional institutions, museums and casinos also benefit from the tried and tested Traka products which are used 24/7 365 around the world, making Traka without any doubt the global market leader in key management systems. Enquiry No: 108

High power electromechanical cylinders

ectra Automation, authorised distributors of Bosch Rexroth products in South Africa, has brought the new Bosch

2014-09-11 15:17:27

Africa’s Vice President – Commercial Sales. Designed and manufactured in the UK, Traka encompasses the following electronic key management systems: Electronic Key Cabinets, Electronic Key Boxes, Key Control, Key Management, Asset Control, Truck Data Logging, Access Control, Lockers and Software. The Traka system has evolved through many years of working closely with some of the world’s largest corporations; development is ongoing to address new opportunities. Whilst every market can benefit from Key Control, Traka Africa specialises primarily in the industrial, medical, aviation, defence, petrochemical and mining sectors.

Rexroth EMC-HD electromechanical cylinders with ball or planetary roller screw drive to the South African market.

The planetary screw drive is designed for high power density and long service life, and the ball screw drive for high dynamics and non-complicated operation. These electromechanical heavy-duty cylinders transmit motor movement via ball or planetary screw drives depending on the dynamics and force requirements. The EMC-HD cylinder is a complete turn-key system for quick and functionally-reliable installation and fast start up – it also comes ready-toinstall. Designed for use in harsh environments and for space-saving integration in machine concepts, the electromechanical cylinders are simple, compact and robust. A screw assembly converts rotary toque into linear motion with high efficiency while the rotation of the spindle enables the in/out piston rod movement via the screw nut. The use of precision screw assemblies allows for precise positioning, high dynamics, powerful drive and a long service life. These cylinders have a dynamic load rating (C dyn: up to 211 kN) and axial force of up to 110 kN. With an integrated anti-rotation device as an option, their maximum traversing speed is standard at 1 m per second and a maximum stroke up to 1 200 mm. Their protection type category is IP65 and a wide range of mounting elements are available with switches and force sensors as optional extras. The Bosch Rexroth EMC-HD electromechanical cylinders, with ball or planetary roller screw drive, are available as a complete system with precisely matching transmissions, servo motors and drive controllers. Enquiry No: 109

October / November 2014

COMPANY & PRODUCT NEWS

KZN Industrial & Business News

Memorandum of understanding to unlock youth potential

Yvonne Zwane, Ithala Group Chief Executive and Professor Mashupye Ratale Kgaphola, MUT Vice Chancellor and Principal

thala Development Finance Corporation Limited, KwaZulu-Natal’s provincial development agency, has for many years been involved in youth development pro-

grammes for learners from previously disadvantaged communities in KwaZulu-Natal by providing much-needed work experience. Internships and in-service training are aimed at giving students a chance to experience the working world in their chosen field of study and are only offered to graduates. The signing of a Memorandum of Understanding with Mangosuthu University of Technology recently, served to cement an ongoing and mutually beneficial relationship established between the parties during 2012. The areas of collaboration include the National Certificate in Bank Credit Learnership, which is jointly funded by Bankseta and Ithala

whereby Ithala has taken on graduates from MUT and DUT and placed them within various departments and divisions in the Group, an 18-month Information Technology Internship programme run for IT Graduates and Ithala’s Human Resources Internship Programme which currently has two interns placed for 12 months. The MOU partnership will also include leadership sessions for executives and management for knowledge-sharing and networking purposes. Also in the pipeline are plans for a sales and marketing academy set up for Ithala SOC Limited distribution channels. “One of the challenges facing graduates

today is a lack of experiential training and Ithala therefore,seeks to forge strategic alliances with like-minded stakeholders such as MUT in order to play a more meaningful role in providing opportunities for learners and graduates to benefit from continuous learning and skills development programmes,” said Ithala Group Chief Executive, Ms Yvonne Zwane. Ithala ascribes to the White Paper presented by DHET (Department of Higher Education and Training), which recognises the importance of partnerships between educational institutions and employers. Several MUT learners have benefited from Ithala’s internship programmes. Enquiry No: 110

Training is a business imperative

he Zest WEG Group has invested R1.5 million in its 200 m² training centre at its Johannesburg head office, which employs a full time training officer. Accredited by the relevant SETA, the South African Institute of Electrical Engineers (SAIEE) and the Engineering Council of South Africa (ECSA), the training centre offers Continuing Professional Development CPD points for its various modules, which have been developed in conjunction with WEG of Brazil. About 848 people have passed through the doors of the training centre so far this year, with a total of about 5 500 since it was established six years ago, Louis Meiring, Zest WEG Group CEO, says. “We started with what we believed were the products most in need of skills development, which was our Automation & Drives division, which comprises a lot of electronic equipment that is more complex than general electric products. It so happened that our initial foray into training was extremely successful,” Meiring says.

This means that anyone can assist customers as everyone has a basic understanding of the business.” Meiring stresses that training is not a marketing tool. “We do not use the training as leverage to sell our products or technologies. We rather take the opportunity after the training has been concluded to interact with our customers. The training period is not a sales pitch; it is strictly about adding value. Enquiry No: 111

Pumps Valves & Pipes Africa expo

lobal forecasts of increased growth in the pumps, valves and pipes sector also reflects market realities and growth predictions in Africa. This is quite evident, based on strong industry support for the forthcoming Pumps, Valves & Pipes Africa (PVPA) Expo next year. A number of major players have already signed up for this popular event, which takes place from 20 to 22 May 2015 at Gallagher Convention Centre in Midrand, Gauteng. Regional and international interest in the PVPA show – now in its ninth year – has never been greater, says show organiser John Thomson of Exhibition Management Services. “Rising global demand for water pumps is a direct result of massive urbanisation and industrialisation around the world,” says Thomson. “Research by Population Action International shows that by 2025, more than 2.8 billion people in 48 countries will face water scarcity; 40 of these countries are in West Asia, North Africa and Sub-Saharan Africa.” The PVPA Expo is proving once again to be an ideal platform for suppliers to reach new and existing markets and explore the opportunities there. Worldwide interest in doing business in Africa is as strong as ever,” says Thomson. Governments around the world – including many in Africa – are pushing industries to recycle and re-use water, and encouraging water pump manufacturers to develop energy-efficient products to reduce power bills of users. “The world’s top 10 water pump manufacturers hold over 50% of the market in highly

competitive developed regions, while developing economies like Africa still offer brighter and more robust growth opportunities, perhaps for smaller players. Africa’s water-related technol-

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Part of this success was due to the decision taken by the Zest WEG Group not to charge its customers for such training and to instead regard it as a means of adding value. The training centre has not only been beneficial in terms of customer training, but has evolved into an invaluable internal resource as well. “It helps us align our staff, from sales to technical, administrative and support, in knowing exactly what it is that we do.

ogy market is expected to grow to $700-million by 2020, and its manufacturing market to $200-billion,” adds Thomson. Enquiry No: 112

Dispensing lubricants just got easier Choose an IPS dispensing option to meet your needs. Single IPS Station • Includes a spill tray, meter, extended hose reel with nozzle and multi-adaptable pump. Multi IPS Station • Includes a spill tray, meter, extended hose reel with nozzle and multi-adaptable pump. • Accommodates up to four products. Horizontal IPS Station • Includes a spill tray, meter, extended hose reel with nozzle and multi-adaptable pump. • Specifically designed for dispensing oil in underground mining operations or areas with height restrictions.

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Single IPS station pictured above.

October / November 2014

COMPANY & PRODUCT NEWS

Importance of cable sizing

Cone crusher demonstrates potential

eflecting its commitment R to expanding its local crusher capability, Weir Minerals Africa

recently commissioned the world’s first Enduron SP cone crusher at a local gold waste rock aggregate plant. Early results indicate that this new technology has significant potential for smaller miners and aggregate producers alike, delivering all the performance characteristics these markets have come to expect of a crusher, but with improved reliability. The cone crusher is characterised by a unique and ingenious design, easily combining light weight, compact dimensions and a robust frame to offer one of the

most advanced cone crushers in the industry. Its innovative design achieves improved energy efficiencies, lower operating costs, reduced frequency of maintenance as well as increased reliability with varying feed conditions, a problem that has beleaguered many suppliers over the years. “Enduron SP cone crushers range from 100 hp to 400 hp, delivering one of the highest production-capacity-per-feed ratios in the industry,” JD Singleton, process manager at Weir Minerals Africa, says. “Cone crusher adjustments and operations are fully automated, and a hydraulic adjustment and locking system allows adjustments under full load. The power of a high eccentric speed, up to 375 rpm, with a larger crushing stroke results in more tons per hour produced, compared to standard cone crushers. In fact, the SP series of cone crushers delivers 30 to 40% more capacity per hour than spring-type cone crushers, according to our data and operational analysis. Enquiry No: 113

New Process Measurement Solution

KZN Industrial & Business News

he terawatt-hour, which carries the symbol TWh, is a unit of energy equal to 114 megawatthours. Simply put, if the energy is transmitted or consumed at a constant rate over a period of time, the total energy in terawatt-hours is the product of the power in megawatts and the time in hours. The TWh is commonly used as a measurement of energy delivered to the consumer for billing purposes. The average monthly energy consumption of a typical non-residential building in South Africa ranges from a few hundred to a few thousand terawatt-hours. TWh usually only applies to industrial consumption as electrical energy delivered to residential consumers is measured in kilowatt-hours (KWh). The European Copper Institute based in Brussels, conducted a recent survey that found that there is a strong economic and saving potential to upsizing cables. This saving could

amount on average to 20 TWh per year. This amounts to an estimated annual saving of 4 TWh for domestic refrigerators, 2 TWh for domestic washing machines and 13.5 TWh for air conditioners and fans. “The vast energy saving potential of upsizing power cables is as a result of the amount of electricity passing through the cables. In final equipment, we can save a big portion of a relatively small end-use. In cables, we can save a little on all electricity use,” says Fernando Nuño from the European Copper Institute. “This clearly suggests that it’s time to focus on addressing and regulating cable sizing rather than increasingly marginal equipment.” The survey, conducted by Egermin Consulting, looked at the relationship between cable sizing and energy savings. Apart from the significant economic savings, cable upsizing could also lead to reduced emissions and the creation of additional jobs. However, in market research conducted across the European Union (EU), it became clear that although the industry is aware of the long-term economic and environmental benefits

Rail benders and jacks

ecker Mining South Africa’s hydraulic rail benders, which have been developed for bending and forming rails on railway lines in heavy industrial and underground transport systems on the mines, easily handle rail up to 40 kg/m. “These rail benders - standard on many South African mines - are powered by 25 ton/250 kN hydraulic cylinders and activated by two stage hand pumps to cope efficiently in harsh operating conditions,” says Eugene Davids, product manager for Becker

Mining South Africa. “These robust rail benders are manufactured locally at the company’s Bellambie Mining & Industrial facility in Alrode, according to stringent quality and safety specifications.” For ease of maintenance, the pump and cylinder are detachable from the rail bender. The main frame of these rail benders are cast and forged from ASTM-E487/78/110 steel and are fitted with specially designed handles

to cable upsizing, the initial installation cost is seen as the most significant obstacle. The second most important consideration is the time and effort of installation. Some respondents conceded that hospitals and other public buildings, industrial plants and green buildings could possibly benefit from the increased energy efficiency and environmental aspects of cable upsizing. Specific applications in these areas include circuits that have permanent loads such as HVAC (heating, ventilation and air-conditioning), lighting, motors, data centres and non-linear power conversion units. Evert Swanepoel, Centre Director of the Copper Development Association Africa (CDAA) has this to say: “It would be important for the electrical industry in South Africa to take note of the increased energy efficiency that correct cable sizing offers as the benefits far outweigh the initial cost of installation”. The Copper Development Association Africa has represented the local copper industry since 1962. Enquiry No: 114

for easy transportation. The back frame section, which provides stability to the unit, enhances portability and facilitates accurate alignment for faultless operation. Becker Mining’s range of hydraulic equipment also includes robust jacks, designed for safe and easy railcar and off-road equipment jacking applications. There are three models of portable ratchet jacks available, with 5, 10 and 20 ton capacities and lift capacities between 330 mm and 457 mm. Enquiry No: 115

ing switch (without guard interlocking) integrated into the hinge. Due to the fact that external actuators are not required with these switches, they can also the high safety level of the Leuze be used problem free in environS420 stainless steel switch ments with high dust concentracomes to the fore. tion levels or with heavy particle Safety hinge switchloads. es essentially unite the Fault-free function is ensured safety switch and door even with warped or misaligned hinge functions in a single doors by means of a repeatable component. setting (switching angle alignment). They are used for the posiThe actuator is integrated into tion monitoring of hard guards the housing while electrical consuch as protective hoods that can rotate by means of a monitor- nection is by means of either a cable or an M 12 plug with optional cable entry from above, below or on the wall or mounting side. This allows for the monitoring of all types of doors, hoods and flaps. The safety hinge switch has an opening angle of up to 180° which can be adjusted as many times as needed.

Stainless steel safety hinge solution Head Office: 012 661 0830 KZN Sales: 082 773 6737 WC Sales: 082 784 0088

www.loadtech.co.za

new stainless steel safety A hinge switch from Leuze that offers an ideal solution for mechani-

cally and hygienically challenging problems in sectors such as the food and beverage, pharmaceutical or cosmetics industries is being distributed locally by Countapulse Controls. These are all industries that require strict cleanliness and hygiene control, which is where

Enquiry No: 116

Mini mobile LED light unit isionX Lighting, supplied by Torre V Automotive, has introduced a Mini Mobile LED Light Unit that provides high-intensity

LED portable lighting in a compact storage unit, only 50 cm high, that can be set up in seconds. The lights lasts up to 12 hours on a full charge and the all-weather unit is supplied with an eight foot extension that will cover any scene with intense light. The mini mobile kit comes with three different lighting variations: 2 DURA Work 4 LED lights, 4 Solo Pod LED lights or 2 Utility Market Square 7 LED lights. Producing up to 6 902 lumens, the mobile unit is suited to emergency response, industrial sites, mining, flagging stations, roadside assistance, scene lighting and any other portable lighting requirement, irrespective of the weather. The case comes complete with a 12 volt output power source that can be used to jump start a vehicle’s battery. The mini unit can be charged using the 12 volt power posts. The unit features a watertight seal when stored, wheels and extendable luggage handle making it easy to transport. Enquiry No: 117

October / November 2014

COMPANY & PRODUCT NEWS

KZN Industrial & Business News

New control-reliable soft start double valve

oss Controls announced the latest addition to its family of industry-leading pneumatic controls, the M DM2 Series C double valve with an integrated soft start function. This modular valve unites the proven ROSS DM2 function with an innovative onboard soft start capability that allows gradual introduction of air to the system when the valve is energized. The valve can be adjusted to provide slower or faster buildup of

system pressure, depending on the ideal setting for your application. This advanced design helps ensure safer start ups, reduces risk of machine damage and enhances uptime. The valve includes Ross’ proven 3/2 normally closed DM2 design which provides dynamic monitoring and memory for CAT-4 systems such as air dump/release applications. Memory, monitoring and air control functions are integrated into two identical valve elements for convenience and enhanced safety.

The M DM2 valve locks out upon detection of asynchronous valve element movement and requires overt solenoid action for reset. The valve rapidly exhausts downstream air pressure when de-energized, removing stored energy for safe access. The M DM2 Series C valve with soft start is enhanced with a modular mounting design, allowing flexible air entry system assembly. This also streamlines inventory and procurement procedures because only one part number is needed, saving time and resources. The valve is also cost effective because its dirttolerant and wear-compensating poppet construction ensures long service life in harsh environments. The series C double valve with soft start also offers; a number of unique features.. Enquiry No: 118

Dewatering solutions with

The PAS dry-prime pumps are best suited for transporting or lifting water with abrasive solids in suspension. Applications include dewatering at construction and mine sites, floodwater or stream diversions and sewage bypass for industries and municipals. “We understand our customers operate in critical situations. In order to get their job done, they need fast and reliable dewatering first and foremost,” says Abet Cantuba, Product Marketing Manager Pumps of Atlas Copco Portable Energy. “The PAS combines high performance with minimum operating expense. For rental companies

Guardmaster 440C-CR30 safety relay meets PLe, SIL 3 per EN ISO 13849-1 and IEC 62061 standards. It is ideal for applications requiring four to nine safety circuits and control of up to five zones. “Machine builders across all industries are seeking safety solutions that go beyond meeting compliance requirements, to helping significantly increase both configuration and operation productivity,” said Thomas Helpenstein, prod-

Upcoming features in January 2015 • Education, Training & Social Development • Industrial Cleaning • Motors, Drives & Transmission • Occupational Health & Safety • Disaster Management, Security & Fire Protection For all editorial contributions contact Chantal Haines For advertising Cheryl Murphy Tel: 031 266 7511 Email: editorial@mediaevents.co.za

For more information on product or service news please circle the number relevant to the article then return it to: KZN Industrial & Business News P O Box 1322 Wandsbeck 3631 or fax this coupon to enquiries at (031) 266 7514 or log on to www.mediaevents.co.za.

and dewatering contractors, this is extremely important as it enables them to get a faster return on equipment acquisition costs, which is exactly what they require to stay competitive.” The PAS 4, PAS 6 and PAS 8 have an operating flow range of 50 to 600 cubic meters per hour with a maximum head of up to 37 meters. Their solids handling capacity reaches up to 76mm. Enquiry No: 119

Simplifying safety implementation

achine builders can now easily implement required safety functions while improving productivity with the Allen-Bradley Guardmaster 440CCR30 safety relay from Rockwell Automation. Users can programme the safety relay through the free Connected Components Workbench software from Rockwell Automation. This free software reduces programming time and helps increase productivity by allowing users to create, control and monitor a safety system in the same software environment as their standard control. The

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diesel-driven pumps

tlas Copco Portable Energy announced a significant expansion of its dewatering pump solutions with the introduction of a new range of diesel-driven portable pumps. The 4, 6 and 8 inch dry-prime units – PAS 4, PAS 6 and PAS 8 – deliver high performance and operating efficiency for the rental and dewatering markets. The company already offers electric, pneumatic and hydraulic submersible pumps. The PAS dieseldriven pumps extend Atlas Copco’s dewatering pump solutions for tough environments or where power is not available.

uct manager, Rockwell Automation. “The flexible, compact Guardmaster 440CCR30 safety relay configured via Connected Components Workbench software meets their needs for improved safety, uptime and productivity.” The distinct graphical user interface and drag-and-drop capabilities of the software help guide users through a simple process of selecting certified safety function blocks for the safety relay. Enquiry No: 120

Name: _________________________________________ Surname:_______________________________________ Designation:______________________________________ Company: _______________________________________ Address: ____________________________________________ ____________________________ Postal Code:_____ Tel:______________________ Fax:___________________ E-mail_________________________________________ Nature of business: ________________________________ Issue 89 - October / November 2014 1

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We don’t know what the car of the future looks like. But we know how it will be built. Making things right. Answers for the future of manufacturing.

To ensure long-term success in the automotive market, production has to react flexibly to its changing needs. Nowadays it is about more than just the mere manufacturing process – product design, production planning, and service performance are also key factors. Volkswagen has already collaborated with Siemens to make production more intelligent. In the future, machines will learn to communicate

independently and to optimize production steps. The goal is to simplify the manufacturing of different car models. The benefits include greater flexibility, ncreased efficiency, and improved global competitiveness. The answers for the future of manufacturing exist. And now is the time to make things right. Because the world of tomorrow needs answers that last today. www.siemens.co.za

October / November 2014

INDUSTRY MOVERS

KZN Industrial & Business News

New Appointments

Seen at a cocktail party hosted by BHF and KPMG at the Hilton Hotel recently from left Dr Vanessa Comley and Alex Winterbash, KPMG; Rachel Wall, WAD Holdings and Nick Matthews, KPMG

From left, are, Lamees Scholtz, BHF; Dr Ayanda Ntsaluba, Discovery Holdings; Lord Nigel Crisp, Independent British Parliamentarian & Former NHS; Dr Gwen Ramokgoba, Former Deputy Minister of Health and Zola Mtshiya, BHF

Phyllis Difeto Chief Operating Officer Transnet National Ports Authority

From left, are, Arno Vorster, Alan Bennett, Tokkie Deysel and Riaan Barnard, LA Health Medical Scheme

John Paine Sales Manager Lovemore Bros Richards Bay

Seen at the monthly meeting for Society of Automation, Instrumentation, Measurement & Control from left, are, Zolile Zoka, Illovo Sugar, Mawande Magwaza, Afrox Durban, Thembisa Promise Mpopomo, Afrox NCP CO2 Plant and James Rwafa, Mangosuthu University of Technology

From left, are, Lucas Esterhuyse and Gail Norton; Gail Norton Instrumentation; Trevor Prior, Priority Safety; Nicolas Hughes, Loadtech Load Cells and Bronwyn Bircham, Gail Norton Instrumentation

Land reform grower honours legacy

t 22 years old, Peaceful Ndlovu set a precedent for South Africa’s youth when he became the youngest land reform grower for agricultural and agri-processing company, Tongaat Hulett. The passionate young man took over the reins of his 95,8 hectare family farm four years after the death of his father. “My father died in 2006 while I was still a minor and the farm was temporarily put under the administration of the executor of his estate. I assumed full responsibility of farm man-

agement in 2010,” said Peaceful. Under Peaceful’s management, and with the support of Tongaat Hulett, farm productivity has steadily increased moving from 2 684 tons of sugarcane in 2010 to 3 455 tons in 2013. The company has provided on-going extension support and facilitated farm-based training on various farming aspects including fertilizer application, cane estimation, knapsack calibration and variety identification. Tongaat Hulett has also assisted Peaceful in progressing applications for grant funding from the Agribusiness Development Agency and the Department Agriculture and Rural Development, which have been successful. In addition to his growing success as a farmer, he has been appointed as a member of the Grower Council and Maidstone Planters’ Association. These bodies represent the farmers’ interests on matters pertaining to farmer development. Enquiry No: 121

Yachal du Plessis Marketing Manager Lovemore Bros

From left, are, Ralph Naidoo, Mangosuthu University; Denver White, CheckIT Systems; Eddie Mohlmann, SAIMC; Guy Coulson, East Coast Solutions and Rob Winter, Automation and Control Solutions

TC Chetty Country Manager for South Africa Royal Institution of Chartered Surveyors

Orion Group’s - Franz and Antoinette Gmeiner

Top employer for third consecutive year THE Orion Group has been officially certified as a Top Employer for the third consecutive year. The annual international research undertaken by the Top Employers Institute recognises leading employers around the world. The research delves into employee conditions, the nurturing and development of talent (throughout all levels), and the continuous optimisation of employment practices. The Orion Group has been awarded the exclusive Top Employers South Africa 2015 certification. The Top Employers Institute globally certifies excellence in the conditions that employers create for their people. It has just announced the results of this year’s research into the employee conditions of significant employers in South Africa.

As part of its contribution towards the Wildlands Conversation Trust, Unilever South Africa unveiled Isibindi, a rhino sculpture, at its La Lucia head office recently. “Isibindi” a Zulu name which means “courage,” was inspired by the courage of field rangers who risk their lives daily to save the rhino from extinction. This sculpture forms part of the Wildlands Rhino Parade campaign, an innovative fundraising drive based on the internationally renowned Cow Parade concept. The initiative seeks to raise funds for, and increase awareness around the war on rhino poaching by getting South Africans to adopt and help design a three quarter life size black rhino sculpture. Isibindi was designed and decorated by a talented team of visual arts learners from Russell High School in Pietermaritzburg.

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