KZN Industrial & Business News - Issue 85 by The Media & Events Company

ISSN NO: 1562 -5702

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February/ March 2014

Management 

Engineering/ Technical Dept. 

R20.90 (incl. VAT)

Until six months ago, the company was utilising outsourced products for treating and dyeing but decided to venture into weavings its own fabric

Challenging China’s textile exports

espite the current economic challenges facing SA industry today, there are those who are prepared to take a chance and make a change. One of these people is Ralph Whiting, CEO of Resource Link Coatings. The company is based in Pinetown, and both weaves and coats fabric for a range of printing methods. Until six months ago, when the weaving section was created, the coating and dyeing section had to make do with fabric imported from China and various local supplies. According to Ralph, this presented a number of problems in terms of quality, both of the fabric as well as the chemical coatings applied to facilitate printing, and resulted in a lot of wastage. In fact, the exchange rate created a ‘perfect storm’ sit-

Buying Dept

uation where cost and quality of imports made it a viable option to set up on home soil. The trade off became one of walking away from the business idea or cutting margins and improving products. The company took the later option and is showing positive growth. The company’s success also lies in the fact that those in management are well trained in the art of ‘getting it right’. With the constant changes and advancements in printing technology, the fact that Ralph is a chemical engineer, and his General Manager, Kevin Hendrickse holds a PHD in chemistry, allows the company to keep its finger on the pulse of the ever changing technology in the printing industry and keep up to date with coating formulations. The company currently has two coating machines and two dyeing

machines and employs 30 staff – growing from the nine in the weaving section who were involved only six months ago. Commenting on the way forward, Ralph explained that the aim was to “get way better at operation and unlock capacity”. In this regard, he also feels that the factory is perfectly based in Pinetown, to cope with future growth. “Rather than any other centres in the country, I feel that Pinetown is the perfect place to set up shop. All the necessary services that may be needed on a day to day basis are readily available from the variety of businesses in the area. “From parts to chemical supplies, to the expertise required to make this business a success”. Enquiry no: 1

Warwick Triangle Development plan on cards

he multimillion rand Warwick Triangle re-development project has been given the green light by Council and it is set to change the face of the City. City Manager, Sibusiso Sithole said that the Warwick Triangle is an important economic hub within the Municipality because commuters converge at the Warwick Triangle using road, rail and taxi transport to and from the City, and this development would help ease traffic congestion and improve cleanliness in that part of the City. Sithole emphasised that the Early Morning Market traders would not be negatively affected by the development. He said the infrastructure at the market would be refurbished, but the construction of a retail centre, new taxi ranks and ablution facilities formed part of the broader development plan for the area. For the first phase of the development the Municipality will invest about R112 million in a nonmotorised platform and taxi rank. According to a report presented to Council, Berea Station Mall (Pty) Ltd together with the Passenger Rail Agency of South Africa (PRASA), being the developer for the R500 million train station upgrade, retail and commercial development will ensure that the upgrade project is of acceptable quality and comply with world-class standards. In 2010 the project was delayed due to the possible and proposed relocation of informal traders at the Early Morning Market. Deputy Mayor Nomvuzo Shabalala assured Council that an extensive consultation process would take place with all stakeholders to ensure that the development becomes a success. Enquiry no: 2

Marketing Dept 

Issue no. 85

Inside

Westmead in demand - page 3

Pumps, Valves, Pipes & Fittings page 7 Forestry, Pulp & Paper page 19 Power Generation - page 25

Packaging - page 29

Consulting Engineers - page 31 Instrumentation, Measurement & Process Control - page 33 Engineering Supplies - page 38 Company & Product News page 41

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February / March 2014

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KZN Industrial & Business News

Local power line industry still under threat

espite being designated in December 2011 by Trade and Industry Minister, Rob Davies, for domestic production prescribed as content in the public procurement system, the South African power line industry’s existence remains threatened because of imports. According to the Southern African Institute of Steel Construction’s Kobus de Beer the situation is dire. “We continue to lose jobs hand over fist and the local power line industry remains threatened. Designation was gazetted in December 2011 and by December 2013 less than 1000 tons of pylon steel was fabricated in South Africa with more than 31 000 tons imported in the same period.” De Beer is adamant that, while the situation is farcical, no one entity is responsible. “Take for example the current situation where Eskom’s total orders to date only account for some 500 tons purchased under ‘designation’. To add to

the concerns, Eskom has just announced that they have received approval from Treasury for 1000 km of power lines to be built ‘out of des-

ignation’ because of a substantial World Bank loan, where the conditions thereof stipulate that no part of the money received can be used in any “protectionist” scheme like, for example, designation. Can Eskom be held responsible for their request to ignore designation when an organisation like the World Bank makes such an offer?” de Beer says. The fact remains that this is a very significant blow to the designation process and the protection of the local industry. The 1000 km of power lines represents approximately 32 000 tons of transmission tower steel, which, in turn, means the loss of a further 3 200 jobs. “It’s a sad situation. Just when we thought that designation would go a far way to rectify the historical challenges to the local power line industry, the circumvention, for whatever reason, of the gazetted law continues to stunt development. An understanding of the history of the struggle for designation of the local power line

industry makes the situation more exasperating. During 2008 imports of fabricated power pylon steelwork rose to 12 425 tons from 1041 tons the previous year, mostly supplied from India at extremely low prices, later proved to constitute “dumping”. Local industry found itself in the frustrating position of not participating in the growth of their market. The crisis did not improve in 2009 as overall activity levels were down. In November 2009 BUSA (Business Unity South Africa) met with Minister Davies and tabled a list of 22 products / industries in crisis. This was the result of extensive consultation with industry to select worthy “problem cases”. The Minister studied these crisis cases and advised the industries to follow the formal system of making applications through the International Trade Agreements Council (ITAC). In April 2010 a formal ITAC application was submitted. This required considerable effort and cost on behalf of the industries with care needed to stay within the constraints demanded by the Competitions Commission. By August the application had been processed and in March of 2011 the imposition of a 15% Ad Valorem Import Duty was gazetted, bringing power line products in line with all other types of fabricated structural steel products. ESKOM promptly applied for and received exemption of these duties on existing contracts, thereby limiting the increased cost effect of duties on electricity prices. In December 2011 Minister Rob Davies announced the designation of a number of products which included power pylons. A specific local content target is set for different products and in the case of power pylons it is 100%. A further notice from the DTI allowed the import of the raw steel requirements as these would be deemed local content – this has not yet been used by any fabricator. But in 2011 imports of Power Pylon steelwork remained high at 15 857 tons and during the first 11 months of 2012 a further 10 011 tons of imported power pylon steelwork arrived. “In short, in the three critical years since 2010, when the process of getting the industry designated began in earnest with the submission to ITAC, the total imports has been 31 920 tons,” says de Beer. “And so, while there has been much work, nothing tangible has been achieved to date. At least three companies have had to close down and others are threatened, at least 650 decent permanent jobs have been lost and more are under threat,” says de Beer. Can the power line industry still be saved? “Of course it can,” says de Beer. “A major part of the solution lies in getting the “designation” to be effectively applied and for discussions with Eskom, the DTI and other reasonable entities to continue unabated. SAISC’s recently formed Power Line Association of Southern Africa (POLASA) will continue to work towards a solution,” concluded de Beer. Enquiry no: 3

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February / March 2014

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KZN Industrial & Business News

Westmead in demand P inetown, with its strategic location between Durban and Pietermaritzburg, and easy access to the N3 as well as other key routes to the north and south coasts of KwaZulu-Natal, has always been extremely popular as an industrial hub, says Nigel Atherstone, JHI Properties KwaZulu-Natal leasing and sales consultant. “A prime hub within the Pinetown area is Mahogany Ridge Industrial Park, situated right in the heart of Westmead – an area which has experienced burgeoning growth over the years. From being an industrial part of Pinetown, Westmead has spread out in all directions and is bordered by the N3 freeway leading to Gauteng, the M13 towards Kloof and the M19 to the south coast,” says Atherstone. “Some 20 years ago a large tract of land was purchased from the

Mariannhill Monastery which has subsequently been developed into Mahogany Ridge Industrial Park, which borders the N3 and which is sometimes referred to as the ‘new’ Westmead. The strategic location of Westmead ensures its ongoing popularity as a key industrial node,” he says. “This is coupled with the fact that it offers realistic rentals and security,” he adds. JHI recently concluded two sizeable leases for industrial space in Mahogany Ridge Industrial Park on behalf of a warehousing/storage operation and a distribution operation. The combined total value of the leases is R37 million. The first lease is for some 4200 square metres of space comprising warehousing of approximately 3900sqm, offices of about 394 square metres and a yard of some 2000sqm. The warehousing includes

Dube TradePort CEO, Saxen van Coller, and Khuphuka Kings Airways Chairman, Dr Musa Mdluli

new air cargo carrier is set to commence regular flights into Africa from Durban’s Dube TradePort, home to King Shaka International Airport. Khuphuka Kings Airways, a new local airline owned by Khuphuka Investments Holdings, has secured scheduled flights between Durban and Lubumbashi, in the Democratic

Republic of Congo, with stop-overs at Ndola, Zambia. The airline is poised to utilise three cargo aircraft, including two ILyushin 76 and one Antonov- AN 12 cargo planes. Although Khuphuka Kings Airways will initially commence operations in the cargo field, plans are in place to also introduce passenger aircraft to the route and to later

two large roll-up doors with canopies leading to the hardened yard, allowing for receiving and despatch. The other lease is for a distribution operation which has occupied 7400sqm of space which is close to their existing operation. Says Atherstone: “In addition to needing to be in close proximity to their existing premises, ease of access to freeways was also a major consideration. Their leased facility comprises approximately 6000sqm of warehousing, around 1400sqm of offices and a yard of approximately 5000sqm. The warehouse offers double volume stacking height while multiple loading docks and dock levellers were priorities for this tenant.” He says a variety of different businesses, including a large component of distribution, manufacturing and logistics operations, are currently seeking industrial space in

convenient, accessible locations. Occasionally this includes overseas companies. Contributing to the demand for industrial accommodation in Westmead and Mahogany Ridge Industrial Park is the fact that the area is saturated with no more land available for developments in the area.

“The area includes a mix of large users as well as mini-factories. Where large factories have been developed, they have always been let and currently there is certainly no surplus of large premises available to let in the area. Among the standalone properties, the size varies from approximately 800sqm to 30 Enquiry no: 4 000sqm,” he adds.

Dube TradePort opens new cargo opportunities for KZN

expand into other parts of Africa. The International Air Transport Association’s (IATA) airline industry forecast for the period 2013-2017 indicates that Africa is the fastest growing region in the world in terms of airfreight volumes and Dube TradePort Corporation’s own cargo strategy is aligned to this forecast. Commenting, Dube TradePort Corporation Chief Executive Officer, Saxen van Coller, said: “We are working to build rapid cargo growth and aim to significantly increase direct air services to and from King Shaka International Airport, transforming KwaZulu-Natal into South Africa’s primary alternative gateway.” She added: “In broad terms, our

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cargo strategy is to target routes in East, Central and West Africa before looking to expand globally, inclusive of the Far East, North America and Europe. The launch of this new route will most certainly serve to increase connectivity between Durban and Central Africa, assisting in the generation of economic efficiencies for our local business community.” It is estimated that no fewer than 85% of KwaZulu-Natal-based companies with goods destined for other parts of Africa currently deliver their airfreight to Johannesburg by road in order to utilise flights from OR Tambo International Airport. With the introduction of new scheduled flights from Durban into various

parts of Africa, local companies will be in a position to reduce transport costs and time by negating the need for the road-freight leg. The Antonov- AN 12, with a carrying capacity of 20 tons, will assist in supplementing loads on the route, while the two ILyushin 76 planes, also geared to fly the route, each have a carrying capacity of 46 tons. The ILyushin 76 aircraft enjoy the added benefit of having an incredible range, giving them the ability to fly anywhere in the world from Durban, ensuring Khuphuka Kings Airways capacity to airlift cargo to any destination in the world. Enquiry no: 5

2013/08/13 1:07 PM

February / March 2014

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KZN Industrial & Business News

R1 Billion investment in new Corolla production

oyota South Africa Motors (TSAM) recently celebrated the start of local volume production of the new Toyota Corolla – the 11th generation of the world’s best-selling car. The R1 billion investment is the second to be announced in the current phase of capital expansion that started with the R363 million new Parts Distribution Centre in Gauteng in 2012. This phase follows a R8 billion investment programme that was completed in 2008 and that saw Toyota’s local production capacity increase to 220 000 units. “It is hard to believe that a mere two generations of the Corolla ago we were a manufac-

turing operation with South Africa as our sole market. Today the Corolla, a good example of leading edge technology, is manufactured in high volumes for both the local and the export markets,” says Dr Johan van Zyl, President and CEO of Toyota South Africa Motors. The success of Toyota and the automotive industry’s transformation from local manufacturing and assembly operations to globallyfocussed manufacturing facilities is due to the successful implementation of the government’s Motor Industry Development Programme, which was designed to encourage high volume local manufacturing and export programmes. The environment created by the MIDP, and subsequently the challenges posed by the new Automotive Production and Development P r o g r a m m e (APDP) allows vehicle manufacturing facilities to invest in long term projects that have long investment horizons.

KZN Premier Mr Senzo Mchunu and Dave Finch, Senior Vice President Manufacturing in the new generation Toyota Corolla at the Toyota Corolla Line-off Ceremony “The decision to invest in the production of the new Toyota Corolla is one taken well in advance of the start of production and one that considers the future economic prospects of South Africa and that of major Corolla export markets. We believe that despite the current economic slowdown and currency pressures the South African built Corolla will prove to be a good long term investment,” says Dr Van Zyl. “The seven week long production disruption in the last quarter of 2013 damaged our reputation as a trustworthy and stable supplier of vehicles. We will have to work hard to find a mutually beneficial solution with our labour partners to stabilise production for both the

local and export market,” says Dr Van Zyl. The new Corolla is a brand new vehicle that offers a new level of technology and refinement for Toyota in the C segment. Says Calvyn Hamman, Senior Vice President of Sales and Marketing at Toyota South Africa Motors: “The new Corolla is a new vehicle in every way and represents some of the best technology that Toyota has to offer in this very important market segment. The fact that South African produced Corollas will be on sale in Africa and Europe is a feather in the cap of local engineering capabilities.” Enquiry no: 5

Growth remains stable in banking industry but challenges lie ahead

lobal Credit Ratings (GCR) recently announced its South Africa Bank Bulletin results which gave an outlook and overview of the latest developments in the economy, regulatory environment and banking industry in South Africa. Dirk Greef, Sector Head: Financial Institution Ratings at GCR, says, since 2003, South Africa has averaged quarter-on-quarter real GDP growth of around 3.3%, reaching a high of 7.2% in 3Q of 2004 and a low of negative 6.3% in 1Q 2009. “Overall, South Africa evidenced a seasonally adjusted and annualised real (“SAAR”) reduction in GDP at constant 2005 prices of 2.5% in 2012 (2011: 3.5%; 2010: 3.1%), to register the first deceleration in GDP on an annual basis since 2010.” He says financial soundness indicators remain strong although rising risks from unsecured lending have been noted, given the high household debt burden. “Consequently, should the interest rate cycle turn and/or house prices fall, at the current elevated debt levels, the household sector and related credit providers exposed to this sector could be very vulnerable,” explains Greef.

He says the subdued economic growth is attributed mainly to labour unrest in the mining and agricultural sectors that crippled production. “A major turning point was the strike at Lonmin’s Marikana platinum mine, marking the mid-point of 3Q. In addition, South Africa’s largest trading block (the Euro zone) slid into a recession over the same period, thereby impacting export volumes.” Furthermore, Greef says the South African Reserve Bank (SARB) has highlighted the weak economic performance and recurring labour market tensions as a significant threat to the outlook for South Africa’s financial stability and sovereign credit rating. “The International Monetary Fund also pinpoints the need to improve home-host cooperation among regulatory authorities given South African banking groups’ expansion into the African continent. The implementation of Basel III in January 2013 and the planned implementation of the Twin Peak approach for financial regulation, among other initiatives, is expected to further enhance financial stability going forward,” explains Greef. He says the inflation reading remained elevated during 2013, after

declining to a review period low of 5.5% in June 2013, and has subsequently breached the upper limit of the target at 6.3%. “The weaker currency has exacerbated South Africa’s imported inflation (including that derived from fuel).” The SARB has indicated that Consumer Price Index (“CPI”) inflation is forecast to average 5.9% in 2013, with a temporary breach of the inflation target range in 3Q. “The most recent inflation projects for 2014 are for an average of 5.5%. The risk to the inflation outlook remains elevated, given the Rand’s depreciation and possible second round inflationary pressures arising,” explains Greef. SARB has indicated that global developments continue to affect South Africa’s economic growth and inflation outcomes, but a range of domestic factors have become relatively more prominent. “The domestic economic landscape worsened as a result of widespread labour market instability, with a general rise in uncertainty and a decline in confidence. As a result, the outlook for domestic economic growth has deteriorated, with the balance of risks to the downside.” concludes Enquiry no: 6 Greef.

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February / March 2014

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KZN Industrial & Business News

Partnership to develop the copper railway G

rindrod Limited, the JSE listed freight and logistics service provider, through its wholly owned subsidiary Grindrod Mauritius, announced the opportunity to work with Northwest Rail Company Limited (“NWR”), to build, operate and maintain a new 590km cape gauge railway from Chingola in the heart of the old Zambian Copperbelt to the Angolan border. These exclusive rights were granted to NWR, a Zambian company, by the Government of Zambia in July 2006. The agreement signed recently will enable the parties to conclude the bankable feasibility study which is currently underway. The railway is to be built in two phases – Phase I extending from Chingola to the Kansanshi, Lumwana and Kalumbila mines (290 km of track), and Phase II to connect with the Benguela line on the Zambian-Angola border near Jimbe. Phase I is intended to service existing ore and finished copper traffic, and Phase II is intended to open up a direct corridor to Lobito which would allow landlocked Zambia to import oil directly from Angola, and to stimulate further mining activity in the Western Copperbelt region. The estimated capital cost of Phase 1 is US$ 489 million while Phase 2 of the NWR project is estimated to cost US$500 million.

Mobile risk to SA companies grows

obile security and device management will become one of the top challenges for South African companies as attacks on smartphones and tablets are likely to increase again in 2014. So says Richard Broeke, a consultant at leading IT security company, Securicom. “Reports from two major security software vendors in 2013 show a consistent rise in attacks targeting mobile devices, specifically Android devices. A lot of them are phony apps, downloaded from third-party app stores and text messaging Trojans that cause devices to send out SMSes to premium-rate numbers. There is also growing numbers of more aggressive apps that act as spyware, working in a similar fashion as spyware on a computer, to harvest the information the criminal wants. “Aside from the personal risk and costs associated with these kinds of infections, employees who use unprotected mobile devices to email, store company data, and connect to the internet or company network, are putting company networks and information at risk,” says Broeke. The increasing number of attacks on mobile devices closely correlates with the growing number of internet-connected devices in the marketplace. The reason why cyber criminals want access to data on mobile devices is simple – it gives them access to an organisation’s intellectual property, the very thing that makes a business unique and profitable. Companies should protect data that resides on mobile devices for the same reason they have long been implementing measures to protect the data on their endpoints and servers. Broeke continues: “What makes this so challenging for business is that data stored on devices in the hands of employees everywhere is difficult to secure without a sound mobile device management strategy, particularly in a Bring Your Own Device (BYOD) environment. Wherever a company’s employees go, data goes too. When there is no policy or technology in place to manage and protect data on employees’ devices, it is vulnerable. Broeke says that most people are generally cognisant that they need some form of security on their mobile devices, and a lot of companies rely on the assumption that employees using their own devices for business purposes will have adequate security. But, he says this is not enough. “Even if they are activated and updated with the necessary regularity, this nature of security software is not capable of protecting the intellectual property housed on a device. For the business, it is about protecting that data, controlling what can or can’t be done with that information, and being able to retrieve it, should the device land in the wrong hands, get lost or stolen. The answer, he says, doesn’t lie in stopping employees from using mobile devices for work purposes. “Mobility empowers productivity. You can

either stifle that productivity by not allowing company info, such as email, onto personalowned devices, or you can embrace it in a controlled fashion and let your staff work the way they live, through collaboration and sharing on devices that they are comfortable using. “It is possible to enforce security and device control, even in a scenario where employees use their personal devices for work. And, it is possible to do so without impacting their experience or the personal data they have on their devices. “But, it all depends on the mobile device management technology that is implemented. By not thoroughly investigating the options available to them and trying save a few rand a month, companies very easily find themselves with an inferior technology, and no real solution to their mobile security or device management challenges. Enquiry no: 8

KPMG’s Infrastructure and Major Projects team have successfully developed the project with NWR over the last twelve months and have facilitated the closure of the deal. Subject to the conclusion of the Phase 1 bankability feasibility study, construction is expected to commence during 2014. Grindrod’s Rail division operates railways and builds, refurbishes and maintains locomotives and wagons provides rail signaling systems and constructs and maintains track infrastructure. Said Dave Rennie, CEO Grindrod Freight Services – Ports & Rail, “This investment will enable Grindrod to extract synergies from our existing investments in the North South rail corridor and our port operations in Maputo, Richards Bay and Durban. “We also see great potential in creating an Atlantic gateway to Central Africa through Lobito and look forward to playing our part in making this a reality with the development of Phase II”. The Copperbelt straddles the border of Northern Zambia and the Southern DRC and is amongst the richest under developed geological regions in Africa. Current production of copper in this area accounts for around 8% of the world’s production, and BMI International forecasts sustained growth in the Zambian copper

industry at five % per annum over the next decade. Said Dave Rennie, “We like the economic fundamentals of the copper market. We have previously been highly focused on the coal and iron ore markets so this gives us a good opportunity to diversify our bulk commodity mix”. Existing copper mines are located in the Eastern Copperbelt and are serviced by smelters located near to Chingola (Zambia) and Lubumbashi (DRC). New mine developments have started, and more are planned, in the Central and Western Copperbelt area of Zambia which need to transport ore up to 300kms for processing. Road infrastructure is poor, and the cost of road transport is becoming prohibitive. An alternative rail transport solution will be both more economic for the North Western province of Zambia and much less damaging to the local environmental. Said Enoch Kavindele, “Grindrod has proven itself to be a good custodian of state assets elsewhere in Africa and I believe that as Zambians, we can be pleased to have them as our partners in this important project which will create thousands of jobs in the country in accordance with government policy”. Enquiry no: 7

February / March 2014

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KZN Industrial & Business News

City launches workplace experience programme

nvesting in youth development is important if we are to see the economic development landscape being changed in the eThekwini Municipal area and to this end, the Mayor of eThekwini Municipality, Cllr James Nxumalo, recently launched the Work Experience Programme at the City Hall. The Programme will assist graduates and those who are working towards the completion of their quali-

fications obtain work experience and access to labour markets. This comes after eThekwini Council last year promulgated the Corporate Education Policy (CEP) which regulates the entry and exit standards of graduates and seeks to help them acquire work experience, internships and in-service trainings occupationally directed to help students complete their qualifications. “This will help graduates acquire

adequate, appropriate and quality workplace skills that will allow them to enter the labour market, increase their employability and gain enough skills to start their own businesses,” said Nxumalo. Nxumalo said this programme will also assist in establishing and maintaining a mutually beneficial relationship with education institutions and other stakeholders in eThekwini and potential employers youth.

It was important to build a nation of productive young people and help them gain proper skills through being in the workplace. One thousand vacancies for work experience opportunities are available for graduates to fill, while 600 graduates have already been engaged in Municipal Departments as part of the programme. “Through the CEP we have decided to standardize the programme and ensure that all departments within the Municipality conform to a standard and this will be achieved

Funding model to build schools in KZN

he development and growth of the KZN Northern Growth Corridor (‘KNGC’) is critical in securing the economic future of the province. Of particular importance is ensuring a steady stream of qualified workers into this expanding economic growth node, making investment in educational facilities a vital component to the future of the region. The iLembe municipality, for example, is expected to experience population growth of 48 500 people a year and already the at-capacity schools in the area are struggling to meet the demand for new scholar intakes. This is great for the region and the local economy, but does put additional strain on the area meaning that infrastructure and social facilities are needed to support this growth. Along with this rapid economic growth comes a massive influx of

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people, particularly in areas such as the Dube TradePort. Providing a sound education infrastructure will ensure that as economic activity in the area increases, residents possess the skills to take advantage of the business and employment opportunities that will arise. “Without an investment in education it will be difficult to empower future generations so that they can fully access the advantages of a growing and sustainable regional economy,” says Leon Bezuidenhout, Corporate Finance Advisory Senior Manager at Deloitte. Peggy Nkonyeni, the KwaZuluNatal MEC for Education recently said that “the National Development Plan says all children shall have access to decent and formal education.” She added that “if our education system is to produce the capable, skilled and empowered people who can turn South Africa into the just and prosperous nation of our dreams, we must overcome the years of neglect which left most of our children without proper facilities for their education.” The solution, Bezuidenhout argues, lies in alternative funding structures to meet the schools’ infrastructure backlog currently in existence. “Substantial additional funding can be accessed for the area by inviting the private sector to invest in social infrastructure assets. The associated project

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Enquiry no: 9

development and operational risks will be transferred and shared between provincial government and the private sector. The benefit will be seen through increased and accelerated development of vitally needed educational infrastructure in the region.” This is the reason behind the appointment of Deloitte, together with consortium partners SMEC, Ledwaba Mazwai and Luthuli Sithole, as transaction advisers to the KZN Education Department charged with investigating the provision of schools infrastructure through private sector involvement. One of the prime target areas for interventions through the project will fall within the KNGC and the iLembe district in particular. Although the four municipalities within the iLembe area as a whole had shown fairly positive education results in 2013, with an overall 72.4% matric pass rate, the statistics for the rural inland municipalities of Ndwedwe and Maphumulo that fall within the economic development zone were noticeably weaker and could see huge benefit from improved physical infrastructure and access to the latest educational technologies. “Although the mandate is from the Department of Basic Education, we hope to see the Department of Higher Education and Training following suit with similar models to address the need for additional Further Education and Training (‘FET’) facilities”, added Bezuidenhout. This is particularly relevant in that there is currently only one public FET College operating in the KNGC area, namely Umfolozi College, which has 5 campuses, Chief Albert Luthuli, Eshowe, Esikhawini, Mandeni and Richards Bay. Enquiry no: 10

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through the collaboration of other stakeholders,” said Nxumalo. The following programmes are on offer: • In-service Training for students who are enrolled by education institutions, but their qualification requires them to be in the workplace as part of their curriculum in order to finalise their qualifications. • Work Experience offered to those who had completed their qualifications but who do not have skills required by the labour market. • Internship are offered to those who had completed their qualification but necessitate them registering with the professional bodies/councils of their qualification.

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olumbus McKinnon Corporation (CMCO) made a successful move from Velbert to Wuppertal, Germany. What made this move impressive, besides the logistics of moving an international company and warehouse, was that it was managed with no discernible impact on business as avoiding downtime and any disruption to CMCO customers was key. On-going company growth meant that the old premises in Velbert became cramped, with rented space creating a labyrinthine structure resulting in heavy in-house traffic and inefficient processes. The new premises in Wuppertal was designed and built to exacting standards, providing 9500sqm of warehouse space and 2500sqm of office space equipped according to the latest environmental and energy standards. The core of the new location is the high-rack warehouse with warehouse navigation software. CMCO used the building of the new premises to optimise logistics processes, improve internal logistics and to redesign the production of the modern electric chain hoist according to lean management principles. In addition to this, the new logistics system will significantly improve delivery times. An event like this does have an impact on CMCO customers globally, and the South African team will certainly experience the benefits of the improved logistics processes. Pieter Nortje, Managing Director of the South African subsidiary, CMCO Material Handling says “this move will result in increased efficiency, which is a benefit we are delighted to pass on to our own customers”. Enquiry no: 11

February / March 2014

KZN Industrial & Business News

PUMPS, VALVES, PIPES & FITTINGS

PVC pipes heavy metal free by 2015

he South African Plastic Pipe Manufacturers Association (SAPPMA) has welcomed the South African Bureau of Standards’ (SABS) announcement that all PVC pipes manufactured in South Africa have to be free of heavy metals by July 2015. General Manager at the SABS Certification, Gauteng, Sibongile Dhlamini, confirmed that the technical committee of the SABS Standard Division has amended the series of standards to ensure that all heavy metal stabilisers are removed in the manufacturing of PVC Pipes. “Local manufacturers of PVC pipes who are SABS certified have been granted a window period of 24 months as of 30 October 2013 to get their house in order and to comply with the new relevant standard requirements,” Pipes bearing the SABS mark of quality would have to be resubmitted for testing, after which new permits will be issued. Commenting on this announcement, SAPPMA Chairman Jan Venter said that the association welcomes the decision by the SABS. “Representing a socially responsible industry, SAPPMA embarked on a voluntary removal of heavy metal stabilizers from PVC pipes back in 2006 because it added value to SAPPMA’s life cycle thinking and took into

account end-of-life issues and waste management options. The reason for the initiative was based on health and environmental considerations and was done at considerable cost to our members,” Venter explained. The policy was fully implemented by SAPPMA in July 2009 and applied to drinking water systems as well as sewer, drainage and mine pipes. “Although lead does not leach from the plastic pipes and does not pose any danger to people once installed, we felt compelled to create a safer environment for the manufactur-

Sund-Aespump KZN Ind 270 x 65* 10/8/13 6:27 PM Page 1 C

ers where lead poisoning does pose a risk for their workers. As a result, all PVC pipe manufactured by SAPPMA members are lead-free and are stabilised with environmentally friendly materials such as Calcium Zinc or organic based stabilisers instead. Adherence to the policy has been a requirement for SAPPMA Membership over the past 8 years, and as such has formed part of the regular SAPPMA factory audits”, Venter said. “In the interest of the consumer and good business practice, the SABS strongly promotes the highest possible product quality standards as well as environmentally friendly manufacturing processes and materials. We therefore urge companies to ensure they comply and begin the process of removing heavy metals from their manufacturing process, if they have not yet done so”. For more information about the new standard, visit https://www.sabs.co.za/Business_Units/ Standards_SA/Controls/Published_Standards/ PS138H.PDF. PVC pipe manufacturers needing assistance with the process can contact SAPPMA on (011) 314-4021 or via email at admin@ sappma.co.za or www.sappma.co.za Enquiry no: 12

A new development in pump impeller design

he design of Waste water pumps has remained unchanged for decades and very little research or development has been undertaken to improve these older designs or to improve efficiency to create improved flow through the pump. Recently however, things have changed and in the endeavour to save water and the planets fragile resource, the present day water to solid ratio has changed markedly. This reduction of consumed water by, for example, the use of half flush cisterns has lead to more frequent clogging and inefficient pump operation. This reduction in the water to solid ratio is a world wide phenomenon which presented an opportunity for the development of an impeller design which was simpler and more hydraulically efficient. Grundfos A/S’s research and development centre was tasked with this problem and have been working on a brand new state of the art hydraulic design. The

result has been the unique “S Tube” impeller design. With efficiency and service life being the criteria the new impeller is balance in air and in water to create a smoother running unit with very little vibration and therefore longer service life. With the S Tube impeller you get the highest efficiency and the largest free passage, lowest vibration and with no edges or dead zones within the pump. There is also no need for cutting functions. This new design has been on test for the past four years by a number of large waste water operators including Thames Water in the UK to establish and prove the integrity of the new design and test the trouble free operation whilst monitoring and maintaining the highest possible efficiency. Grundfos A/S believe they have developed the ultimate in waste water pump technology with the best wire to water efficiency yet Enquiry no: 13 seen. Composite

Optimize logistics. Connect to Control. With its new contactor and motor control range, ABB has reduced the number of contactor coils from 45 to 4 and the number of product variants has been reduced by as much as 90%. New technology adds functionality in addition to simplified stockholding and reduced administration costs. www.abb.co.za/lowvoltage

ABB South Africa (Pty) Ltd Tel. +27 10 202 5000 E-mail: LP@za.abb.com

New AF Contactors 2013(Landscape).indd 1

2013/10/17 10:49:35 AM

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PUMPS, VALVES, PIPES & FITTINGS

February / March 2014

KZN Industrial & Business News

Durban water supply project accelerated T

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he awarding of key construction contracts for the Western and Northern Aqueducts would see the end of Durban’s tenuous water situation and provide businesses and residents with an assured, sustainable water supply within the next three years. Neil Macleod, head of eThekwini Water and Sanitation (EWS) said that following the release of additional funds, projects had been accelerated in order to meet the city’s need for bulk water infrastructure. Macleod has made no secret of the fact that lack of an assured water supply has already begun to restrict the progress of projects within the Dube C

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Tradeport, Bridge City and Cornubia. An assured water supply was critical if development both in inner west and key northern coastal corridor was to gather momentum. “We have enough water to meet the current demand but we don’t have the infrastructure to deliver it to where it is needed most. To the north, we don’t have the network capacity to supply water.” “From this year, we’ll start slipping back to where the supply is not statistically able to meet demand,” he explains. The first phase of the Western Aqueduct which covered 19km from Umlaas Road to Inchanga Station was

commissioned in June 2011. The second phase of the Western Aqueduct - Durban’s largest ever water pipeline – is expected to significantly strengthen the capacity of bulk water supply to the western regions of eThekwini. The initial stages of the Northern Aqueduct will augment the existing system and will ensure higher volume availability at Waterloo and Umhlanga as well as provide water to the proposed new Blackburn reservoir, he said. Martin Bright, Project Manager for the Western and Northern Aqueduct projects said that work on the second phase of the Western Aqueduct was already progressing well. After running into a number of unexpected delays, EWS decided to unbundle this mega project into individual contracts that would be rolled out over a seven-year period. Cycad Pipelines was awarded the first contract for the 7km stretch between Inchanga Station and Alverstone Nek in April in April 2013. Construction is already underway and is expected to be complete by the second quarter of 2015. The second contract, which begins at Alverstone Nek and continues to Ashley Drive in Hillcrest, was awarded to WK SA Construction in August last year. Construction has also begun with completion expected during the first quarter of 2015. The contract for the largest segment of the pipeline which measures 25 kilometres from Ashley Drive in Hillcrest to Ntuzuma has just been awarded to Esorfranki Construction. Work on this section should be complete by the first quarter of 2017. The contract for the Ashley Drive reservoir has been awarded to Icon Construction. It will be commissioned by the fourth quarter of 2015. The Northern Aqueduct was kick started this year with the awarding of the first contract which will begin at Phoenix 2 reservoir and extend to the Umhlanga and Waterloo Reservoirs to Esor Franki Construction. A second contract for the pipeline stretching from Duffs Road to the Phoenix 2 Reservoir should be awarded Enquiry no: 14 shortly.

Celebrating a year since registration

etso’s ownership compliant black empowered company celebrates a year since registration. Ububele Trust, the owners of partners Ububele Capital, play a pivotal role in the drive to provide sustainable solutions to the company’s mining and construction customer base. Scott Pringle, General Sales Manager of Metso Mining and Construction, says “We have the capability to provide onsite servicing solutions with full plant optimisation to drive operational costs down. We believe we have a strong winning formula that not only yields savings but also fully complies with the BBBEE and Mining Charter legislations”. Metso has positioned itself to meet the demands of the market. With the cost pressures facing the Mining and Construction industry and the strict 2014 legislative targets looming Metso has clearly structured it’s offering to be attractive. One of the key values of the corporation is driving customer success. It was this value that drove the company to develop its product range and create the black empowered company. The company has embraced the transformation concept behind SA’s legislation and looks forward to playing a part in making the success sustainable. For any Mesto sales and service enquiries in KZN please contact Pumpserve, who are the sole appointed agents for Metso in KZN. Enquiry no: 15

February / March 2014

KZN Industrial & Business News

PUMPS, VALVES, PIPES & FITTINGS

Dangers of pirate pump parts

any companies use high flow, high pressure peristaltic pumps in their treatment processes – and it’s no surprise to learn that there are just as many manufacturers out to make a ‘fast buck’ by supplying counterfeit or ‘pirate’ replacement parts for these pumps. However buying non-standard replacement hoses for pumps is false economy. “Using pirate parts can reduce a pump’s efficiency by up to 30 percent,” says Reon Durgapersad (pictured), Watson-Marlow Bredel KZN and Eastern Cape area manager. Lower efficiency levels, higher power requirements, greater wear and increased maintenance – which invariably accompany cheaper alternative offerings – are overlooked in the face of perceived significant savings. Using OEM genuine spares may cost a little more, but cost benefits in the end include fewer breakdowns, better production and qualified and trained personnel to assist when problems arise. At one installation using Watson-Marlow Bredel 100 pumps, the result of using inferior hoses was two cracked pump housings that

added up to extremely expensive replacement costs. Bearing failures due to uneven loading and/or overloading – and stemming directly from variations in hose wall thickness – can have serious consequences in terms of operating costs and downtime. “As the only component in contact with the pumped media, the hose is the heart of any peristaltic pump,” says Durgapersad. “Dedicated hoses such as those produced by Watson-Marlow are the end product of continuous research and development. They consist of a thick, resilient inner layer and an outer layer of natural rubber, reinforced internally with braided nylon. “They are produced to close dimensional tolerances – between 0.25mm on larger hose bore sizes and 0.4mm on smaller sizes – and ground to the precise diameter.”

Durgapersad points out that tolerances are of utmost importance in any pump technology. For some pumps, a difference in 0.3 of a mm is huge. In the light of hard facts and figures, it’s difficult to understand how using non-standard parts can ever be viewed as a good business decision. Yet it causes ongoing problems in the industry, particularly in the context of negative impacts on pump performance and system failures, which almost inevitably necessitate additional costs. Figures for hose life are equally in favour of dedicated manufacturer’s hoses, notably on sewage sludge pumping and similar arduous waste handling applications. One example of this is at a site where two identical pumps were installed for the same duty. A maintenance contractor replaced the original hose with a cheaper ‘pirate’ alternative on one of the pumps.

Solutions to the machine reliability barrier

Twelve months later, the original WatsonMarlow hose was still in service. The second pump, using the pirate, was on its fourth hose fitting. In another comparable sludge pumping installation, ‘pirate’ hoses lasted approximately 200 hours, equivalent to about one month’s service – a retrofitted hose is still in service after more than eight months. “It is also important to take into account lack of provenance, non-compliance with standards, the reputation of often little known manufacturers and products with no real validation that the parts being purchased will perform at anything like the required levels and no comeback if they fail to perform,” says Durgapersad. “Add in the complications of compromising original manufacturers’ warranties, with insurance implications where ‘pirate’ parts are used, and the seemingly significant savings on offer very quickly start to unwind,” he concludes. Enquiry no: 16

Excellent Minerals Solutions

WARMAN® Centrifugal Slurry Pumps ENVIROTECH® Centrifugal Slurry Pumps ISOGATE® Slurry Valves

recent series of full-day seminars aimed at improving the reliability of pumps and other rotating machines were recently held country wide. The topics covered included the general principles of mechanical seal function, piping plans approved and recommended by the American Petroleum Institute, and the use of barrier fluids as an aid to total machine sealing. The seminars were attended by a number of petroleum refinery managers tasked with ensuring uninterrupted production and preventing the leakage of hazardous fluids into the atmosphere. Delivering the seminars was Dr Chris Carmody (pictured), special products manager for dry gas seals and sealing systems at mechanical seals company AESSEAL, and is the named inventor of many of AESSEAL’s product designs. A key subject discussed was the mutual interaction of the process fluid, the system, the pump, and industry’s erroneous view of the mechanical seal almost as an added extra. Dr Carmody covered the main causes of seal failures, emphasising the need for the correct system and piping plan to ensure effective sealing and longer mechanical seal life. He also addressed the frustration caused to plant managers by not attaining the anticipated results of the constant drive for reliability improvements – in other words the reliability barrier. A man of exceptional experience in the field of machine reliability, Dr Carmody began his career as a maintenance engineer in the chemical and process industry before joining AESSEAL as the company’s first full time seal designer and development engineer. He returned to academic studies to secure his masters degree in science (structural integrity) and a doctoral degree on the fluid structure interaction of bioprosthetic heart valves. Re-joining industry as a consulting engineer, Carmody worked on such prestigious projects as the A380 Airbus, the award winning Falkirk Wheel and the new Wembley stadium before returning to AESSEAL as special products manager. Today he is responsible for the development of high integrity sealing products including dry Enquiry no: 17 gas seals.

Lower your operational costs with the Weir Minerals Solution In slurry and dewatering pumping, processing and control applications where the cost of ownership often outweighs capital cost as a priority, we help our customers address such issues as longevity, capacity, efficiency of operation and maintenance.

Expertise where it counts

Warman® slurry and Envirotech® dewatering pumps are among the world’s most comprehensive range of pumps for use in mining, chemical and industrial applications. These pumps are designed for ultra heavy duty applications such as mill discharge, process plant and tailings, high pressure pipelines, as well as other speciality applications. Robust design and rugged heavy-duty construction, the Isogate® slurry knife gate valve is designed for long life and high reliability. The Isogate® valve range now also includes Autoball™ 3 way check valves, swing check valves, and a diverse range of mechanical and pneumatic pinch valves.

Copyright ©2012, Weir Minerals Africa (Pty) Ltd. All rights reserved. WARMAN is a registered trademark of Weir Minerals Australia Ltd and Weir Group African IP Ltd; ISOGATE is a registered trademark of Weir do Brasil Ltda; AUTOBALL is a trademark of Weir Minerals Australia Ltd.

For more information contact us on: +27 (0)11 9292600 www.weirminerals.com

PUMPS, VALVES, PIPES & FITTINGS

February / March 2014

KZN Industrial & Business News

R4,3-million pipeline project complete L eading fluid conveyance products and solutions expert Incledon has successfully completed its role in supplying R4,3million worth of pipes and valves to a potable water upgrade project in Vosloorus, on the East Rand of Gauteng. As part of a municipal upgrade project to replace an existing asbestos cement (AC) pipeline that was installed in the 1980s, Incledon was contacted in mid-2012 to supply more than 1.4 km of 560 mm diameter locally manufactured high-density polyethylene (HDPE) pipe. Incledon sales representative for civils, Robinson Patji highlights the fact that HDPE was selected as the material of choice to replace the

existing AC pipeline, due to its high impact strength, low friction properties and environmentally friendly characteristics. “AC pipelines pose some potential health concerns for both workers and end-users. These pipes are also very brittle and tend to crack under stress from trench loads. The brittleness also makes this type of pipe difficult to cut and splice to undertake repair work,” he explains. Patji reveals that HDPE is nontoxic and entirely safe for supplying drinking water, while the lightness of the material makes it an easier and quicker type of pipeline to install. “The lightweight properties of HDPE makes it easier for workers to carry and lay. More pipes can be loaded

onto a truck, thereby reducing carbon emissions as well. HDPE pipes also boasts more impact strength than AC pipes, which substantially reduces the risk of cracking and subsequent leaks.” According to Patji, the SANS 4427 approved pipes, which have a pressure rating of 12,5 bar, were delivered to the project in 12-m-lengths. As part of its comprehensive service offering, Incledon also sourced a professional welding contractor on behalf of the municipality, in addition to supplying the project with a range of AVK valves in sizes including; 200 mm, 300 mm and 500 mm. The contract was officially completed in mid-2013 without any major challenges encountered, states Patji. “Incledon has developed an excellent relationship with the local municipal

council, and assisted with storing the exact product specifications on our database to ensure prompt service delivery. Despite some minor interruptions that were swiftly overcome, the project was successfully completed on time and within budget.” As municipalities across South Africa continue to invest more capital into pipeline upgrades, Patji is confident of the future outlook for Incledon in the civils market. “Incledon has successfully supplied large volumes of piping products to numerous municipalities nationwide, with a number of tenders currently pending. I believe that the potential for future growth in the municipal market is strong, as a result of Incledon’s excellent reputation for providing top-quality products that are backed-up by our commitment to

high levels of after-sales support,” he Enquiry no: 18 concludes.

Two more packages for SA company

Filters, Fittings, Hoses and Flexible Tubing, Leak Detectors, Lubricants, Sealants, Measurement Devices, Miniature Modular Systems, Pre Engineered Sub Systems, Quick-Connects, Regulators, Sample Cylinders, Tubing and Tube Accessories, Valves, Welding System

Head Office Tel: +27(0)11 609-7925 Durban Tel: +27(0)31 569-3300 Email: info@johannesburg.swagelok.com www.swagelok.com

n addition to the major cyclone package currently being installed at First Quantum Minerals Ltd’s new Sentinel copper project in Northern Zambia, Weir Minerals Africa has been awarded two more packages — one for Sentinel and the other for Enterprise nickel, which are also part of the greater Trident project. The first order, placed in mid-2012, represented one of the biggest cyclone cluster installations of its kind ever supplied by Weir Minerals Africa into an African application and included two 12x 650CVX cyclone clusters for the SAG mill application and four 16x 650CVX cyclone clusters for the ball mill classification duties. Commissioning of the equipment is scheduled for the second quarter of 2014. The subsequent package for Sentinel comprises more than 50 Warman AH horizontal centrifugal slurry and AHF horizontal froth pumps, ranging in size from small to large, and 55 Warman vertical spindle pumps capable of handling large volumes. This package also includes the supply of 611 Isogate knife gate slurry valves ranging from 2” to 48” in size with manual, pneumatic and hydraulic

actuation and a high pressure range of 24” high pressure Isogate knife gate slurry valves that include Isogate WS, WB, WBP and WH units. It is one of the biggest Isogate knife gate

valve orders that Weir Minerals Africa has received on the continent to date. The third package comprises all the cyclones needed on the Enterprise nickel project — one cluster of 10 Cavex 500CVX hydrocyclones and two clusters of four Cavex 500CVX

hydrocyclones for installation at the Enterprise ball and SAG mills. As with the earlier Sentinel package, all Weir Minerals Africa cyclone clusters are designed and manufactured in South Africa. The company will also supply 53 horizontal Warman AH slurry pumps and AHF froth pumps as part of this order. All these products will be serviced by the Weir Minerals Africa service centre in Kitwe, Zambia, as part of its aftermarket service support for the life of mine. This includes stockholding of spare parts, with backup from the company’s product specialists based in Isando, South Africa. “Being awarded three packages for the Trident project is a clear indication that the market has fully recognised our transition from a historical slurry pump supplier to a world class manufacturer of a host of complementary products, including large cyclone clusters, valves and Linatex rubber linings. Warman pumps are well proven in similar applications worldwide, but these are locally engineered, manufactured and supported here in Africa.” says Weir Minerals Africa’s process manager, JD Singleton.

Enquiry no: 19

Cutting electricity costs

lectric motors are the single biggest E consumer of electricity and they account for about 65% of industries power consump-

tion. Saving electricity as well as reducing your carbon footprint is very important for a more sustainable future and the most obvious way for industry to lower energy consumption, is to employ reliable, highly efficient motors. Reducing energy consumption and improved reliability has a significant effect on costs. Using ABB process performance high efficiency motors not only reduces electricity costs but also improves the process reliability, lowers maintenance costs and therefore the total cost of ownership. The purchase price of these motors works out to be less than 1 % of total cost of ownership . SAW Africa is the Authorised Value Provider for ABB process performance motors and they currently import and stock a full range of IE2 high efficiency motors. The range available from stock is 0.37kw up to 355kw in 400V and 525V, and up to 1000kW can be ordered to customer specification. The main focus of SAW Africa is to supply and provide support for ABB Process performance high efficiency motors to industry, mining and the OEM’s in the country The range is offered with an industry leading 3 year warranty and holds the SABS mark of quality “SANS 1804 1&2 “ Enquiry no: 20

February / March 2014

KZN Industrial & Business News

PUMPS, VALVES, PIPES & FITTINGS

PVC-O pressure pipe supplied to uThukela district

he first 630mm diameter PVC-O Pressure pipe, ranging from PN12,5 TO PN 25 Bar, has been specified and supplied to the uThukela District Municipality’s Contract No. 97/2012, described as the “Driefontein Bulk Water Feeder Main” project, situated near Ladysmith, Kwazulu Natal. Consulting Engineers Willcocks Reed and Kotze (Pty) Ltd have specified the Molecor TOM 500 Bi-Axle Orientated PVC-O pipe for

this project, which will link the bulk water feeder main from the Spionkop dam at the existing Observation Hill reservoir in Ladysmith to the newly constructed 5Ml Hobsland reservoir in the Driefontein Complex. The Contract was awarded to Icon Construction who commenced construction on May 2013 and was on track for contractual completion at the end of February 2014. The contract covers a distance of 10.3km.Future phases will extend a further 47km, thereby providing bulk potable water supply to the greater Emnambithi & Indaka local municipal region. The Molecor TOM 500 product incorporates world leading Orientated PVC-O technology. It offers a long service life, low maintenance, zero cathodic protection requirements, excellent physical and hydraulic properties, and is a tried and tested product with an exemplary track record. This new user friendly technology allows Plastic pipe to be considered, as a viable alternative in the low to high pressure bulk distribution projects. BI-Axle orientated PVC-O pipes are tough and light in comparison to competing pipe materials, which results in markedly improved handling and installation production rates.

Boiler feedwater valves

eedwater valves, as with many other types on a boiler, experience very different conditions during start up compared with normal running conditions. Not only are flow rates lower, but the pressure drop is usually much greater. This results in cavitation damage close to the seat, as well as poor control. One solution used in existing plants is to install a sacrificial valve in parallel to the control valve just to be used during start up. PSV Mitech has developed a control valve with a special trim to prevent cavitation damage.

At the bottom of the retainer are a series of restrictions that eliminate cavitation by gradually dropping the pressure. This is the ZZ design. As the plug opens, the flow then passes through passageways with a smaller number of restrictions. In the top half of the retainer are single-hole restrictions which can handle the high flow low pressure drop condition that the valve experiences in normal running mode. Typically this type of trim would give turndown ratios of up to 200:1. Enquiry no: 23

Enquiry no: 21

Reliable pumps from China

EO’s ACm multistage centrifugal pumps can be used to transfer clean water or other liquids with similar physical and chemical properties as that of water, in temperatures not exceeding 40°C. The pumps are suitable for use in industrial and urban water supplies, irrigation, longdistance water transfer, HVAC, circulation and pressure boosting for cold and hot water and more. The robust pump has a cast iron body and support, both of which have been treated with an antirust substance, an AISI 304 shaft and a +8 m suction capability. The motor is C&U bearing with copper winding and has a built-in thermal protector for single phase type motors. It meets insulation class F and IPX4 protection requirements. Also available from LEO’S are AJm selfpriming jet pumps. Reliable and low maintenance, they are suitable for lifting water from wells, irrigation and pressure boosting of running water. The pump has a stainless steel body and

support, both treated with a special anti-rust substance. It has a stainless steel impeller and an AISI 304 shaft and is suitable for temperatures up to +40°C. Various types are offered from 0,3 kW, 220V to 0,9 kW, 220V.The motor is C&U bearing, has copper winding and a built-in thermal protector for single phase type motors. It meets insulation class F and IPX4 protection requirements. LEO is the first Chinese pump manufacturer to be listed on China’s stock exchange and has the only state-authorised technical centre for physical and chemical testing of pumps and garden tools. The company plays an important role in many critical fields such as civil water supply, agricultural irrigation, industrial water treatment, heating ventilation engineering, power station construction, petrochemical engineering, mining and more. LEO pumps are sold in over 140 countries and regions worldwide. LEO has grown into the largest small-sized water pump manufacturer in China. LEO is represented locally by Raptech. Enquiry no: 22

LEADERS IN THE PROVISION OF

FLUID TRANSFER MEASUREMENT & DISPENSING EQUIPMENT ALSO NOW PITSTOP & RAV LIFTS

WWW.METERSYSTEMS.CO.ZA A division of the Set Point Group

DURBAN T: +27(0)31 700 9974/5 F: +27(0)31 700 9978 sales@metersystems.co.za

February / March 2014

PUMPS, VALVES, PIPES & FITTINGS

KZN Industrial & Business News

Locally manufactured spares L ocal developer and manufacturer of pumps and generic spares, Unique Engineering, is experiencing a rapid upsurge in its replacement component market. According to Sales Director, Peet Hartman, “In some instances customers are saving as much as 40%.” We do believe that due to the weak Rand, this trend will continue. It is where our growth is heading at this point in time.” Over and above the high cost of imported products, the Eco Helical positive displacement pumps and spares perform equally as well, and in some instances better. The pumps have been designed to operate under local conditions. The company is renowned in the mining industry and this specific pump range was launched in 2007.

It has proven its worth as many units are operating in various areas such as water, sewage, effluent, dosing plants, mining and the explosive and chemical industries. There are two units used extensively in applications for flocculant dosing, dewatering plants, as well as areas where waste activated and de-activated sludge water is present. During 2012, the company introduced a custom made unit specifically for efficient dispensing and transportation of explosive emulsion used to charge blasting holes. It is used for underground and open cast applications. The mobile, mounted helical rotor positive displacement pump is manufactured complete with tanks. It is only available from explosive chemical suppliers, who assisted the company with its research and development of the product.

Another string to their pump portfolio is the Wilfo double diaphragm DD 25 and 50 range, known as the ‘work horse’ of the mining industry. It was developed and manufactured locally almost 30 years ago. In the past year, this unit has been redesigned into a ‘lube free’ pump, making it environmentally friendly and non-hazardous. No oil is required to run it, also reducing cost. “Our order book from the South African mining sectors of the market in dosing and gland service water applications, as well as the explosives industry, has shown good results over the past five years,” concludes Hartman. The company has representation in KZN, has recently set up representation in Zambia, Mozambique and other sub-Saharan countries. Enquiry no: 24

New player in HDPE pipe industry

he RARE Group is a distributor and service provider of piping and related products covering the entire fluid conveyance cycle, across all fluid sectors. Based in Kliprivier, Gauteng, the company has, up to late last year, specialised in the trading of pipe-related products, pipeline installation and water treatment. The company, however, signed a deal worth R 30.9-million in November last year which will enable it to manufacture High Density Polyethylene (HDPE) pipes up until 1000 mm in diameter for the mining, infrastructure, agricultural and industrial markets. Rare acquired a pipe manufacturing plant, fixed assets and property in Meyerton. This will be Rare’s first venture into manufacturing HDPE pipes. Rare has also appointed Tony Dean, a very well-known plastic pipe industry leader, as managing director of the new pipe manufacturing division of Rare. The new division will trade under the name Rare Plastics. Dean previously managed some well-known plastic pipe businesses in South Africa and Botswana and comes with over thirty years’ industry experience. According to the CEO of Rare Holdings, Wally van Coller, this acquisition will improve Rare’s competitiveness in offering piping solutions to the industry by supplying a turnkey

service ranging from manufacturing through installation and maintenance. RARE’s Durban branch was recently awarded the contract for the supply of 6km API 5L Grade B pipe in 20 inch diameter plus other piping and fittings to the value of R11.9 million,for the supply of the Back of Berth Enquiry no: 25 project.

New improved alloys introduced

ickel Chrome Molybdenum (Nistelle) N alloys are commonly used for their exceptional resistance to highly corrosive service environments in the paper processing, chemical, petrochemical, and other industries. The new Kennametal Stellite, Nistelle Super C, available for Weartech, has been improved over the traditional composition of the previous product, resulting in improved abrasion and corrosion resistance. It is also easier to finish, with less tear out (galling) during the grinding process. Current and potential applications include a bond cost for ceramic coatings used in the paper industry, roll cover coating used in processing chemical for fertilisers, buildup material for surface restoration where corrosion is a factor, buildup coating where support to a

top coat such as a WC-containing material is needed, coatings applied using hydrogen as fuel may be single point turned, drilled or milled, surface coating where corrosion resistance and significantly increased wear resistance are required and used to restore and improve component life in marine applications such as pump shafts and sleeves. When blended with 75% Stelcar Tungsten Carbide Cobalt powder the wear resistance increases significantly without marked degrading of the corrosion resistance. Nistelle Super C is available in a High Velocity Oxygen Fuel (HVOF) and Plasma Transferred Arc powder while the JK-6806 WC/12 Co containing powder is available in a HVOF Powder only. Enquiry no: 26

February / March 2014

KZN Industrial & Business News

PUMPS, VALVES, PIPES & FITTINGS

Pumps that cut operating costs

or companies in the oil, chemical and water process industries struggling with high electricity bills and accelerating maintenance costs, Sundyne’s centrifugal integrally geared pumps, compressors and sealless magnetic drive pumps represent a superior performance alternative. Local distributor AESPump claims to reduce the operational expenses which can account for as much as 96% of a typical process engineering budget, by customising equipment selection and design to operate at the best efficiency points. AESPump engineers assess the application requirements, and then pass specifications for the correct pump selection and design to the Sundyne factory in Colorado, USA, for manufacture. Over one million customised combinations are available. Sundyne specialises in the design and manufacture of centrifugal integrally geared lowflow high head and multi-stage pumps to ISO 13709 and API-610 standard, and sealless magnetic drive pumps that meet API-685 and ANSI standards. Sundyne pumps and compressors are built to handle hydrocarbons at extremely high pressures and temperatures, conditions likely to render explosive any accidental emissions.

The pumps are designed and manufactured with thick casings, robust seal designs, and bearings, shafts and gears designed to run for years without expensive overhaul or repair. HMD sealless magnetic drive pumps are designed to completely prevent leaks of volatile chemicals in both ETFE lined and metallic models, eliminating unacceptable emissions while advancing worksite safety and environmental stewardship. Sundyne integrally geared pumps are designed to reduce footprints by up to 75%, allowing the customer to make maximum use of available space. Sundyne appointed AESPump as sole authorised channel partner and service provider for South Africa in May of last year, making the decision to grant the appointment after completing a comprehensive audit of the company’s capabilities, which include pump testing facilities, Level 4 BEE certification, full compliance with ISO 9001, 14001 and OSHAS 18001 industrial standards, merSETA approval for apprenticeship training, and flame-proofed apparatus for use in explosive gas atmospheres. Sundyne has been active in South Africa for more than 40 years.

Oil refinery typically set to benefit from the performance alternative offered by Sundyne’s centrifugal integrally geared pumps compressors and sealless

E:\!BMG\#Jobs\Adverts\2014\012014\BMG-PUM27012014-KZN.cdr 27 January 2014 08:37:43 AM Color profile: Disabled Composite Default screen

Enquiry no: 27

Remanufactured hoist drum bearings & components

KF South Africa, global rotating technology specialist, provided a cost saving and delivery lead time solution to one of South Africa’s largest steel producing companies that is under immeasurable pressure to reduce maintenance and production related costs. The steel manufacturer faced global challenges around demand and competitive pricing for rolled steel. In addition, unforeseen breakdowns and delays with regard to the acquisition of new maintainable parts could potentially hampered required performance parameters that ensure the sustainability of the plant. “The company is therefore constantly searching for ways to reduce costs and ensure maximum uptime through reliable equip-

ment,” explains Giscard Lailvaux, SKF Segments / Key Accounts Manager – Southern Africa. The demands for steel are massive and never ending and the company needed a solution fast for a damaged hoist drum and its bearings. The remanufacturing solution offered by SKF South Africa around the hoist drum bearings, which would have previously been discarded, has led to a significant reduction in costs and vastly improved lead time of the required bearings for the steel manufacturer. “Our customer sought and found what they needed by firstly sending the bearings and related components to SKF for inspection to determine suitability of their remanufacture,” states Lailvaux. From there the remanufacturing process was started. The total SKF remanufacturing, which included welding and grinding of the 471.30mm hoist drum and remanufacturing of the applicable bearings, only required a mere fourteen working days to complete and offered further benefits to the company by avoiding unplanned breakdowns, substantially reduced cost with an ROI of over 1500% and enabled the continuance of the intended and permissible service life of the original assembly and increasing equipment reliability. Enquiry no: 28

After 39 years Still the leading supplier of pipes, fittings and flanges to the Petrochemical Industry. STEELY DETERMINATION Our steel pipe is sourced from local and international mills and features a variety of end connections, coatings and linings to suit most applications. We also carry a large inventory and a full range of seamless and welded pipe in various grades to API, ASTM and SANS 719 specifications.

THE POWER OF PLASTIC! RARE Plastics manufacture HDPE pipe in sizes ranging from 110mm to 1000mm. Our pipes are manufactured to ISO SANS 4427 standards.RARE also supplies PVCu and PVCm in various diameters sourced from local manufacturers and fully in line with the relevant SANS and ISO specifications.

info@rare.co.za HEAD OFFICE T: 011 906 8000

www.rare.co.za

DURBAN T: 031 902 2440/5

RARE PLASTICS T: 016 362 2868

PROUD MEMBERS OF SAPPMA AND IFPA.

Other services include pipeline installations, pipelining & water treatment solutions

PUMPS, VALVES, PIPES & FITTINGS

February / March 2014

KZN Industrial & Business News

New technology to manage pipeline scaling

F   

  

  

              

lowrox, a global leader in heavy-duty industrial valve manufacturing and service, is introducing the Flowrox Scaling Watch, a new product designed for the precise measurement of scale in pipelines and other fluid control environments. Scaling is a common problem in the Minerals & Metallurgy, Oil & Gas, Power Plants, Pulp & Paper and Municipal Waste Water industries, where production rates can be adversely affected by the hardening of iron, salts and other minerals in pipes and valves. The Flowrox Scaling Watch is a wafer piece of pipeline engineered for insertion between two flanges for a precise fit that allows the detection of scale, often the result of the hardened mineral deposits that can reduce the flow of fluids through a pipeline. The device uses Electrical Capacitance Tomography (ECT) technology, which allows operators to see inside piping systems without stopping the process or opening up the pipeline, and enables 3D-imaging and measurement of non-conductive media inside process pipelines and tanks.

  

    

      

Enquiry no: 29

Submersible hydro-solid pumps

     

In addition, it utilizes a patented algorithm that creates a 3D image of the process fluid in the piping and generates trend data as well as show free volume inside the pipe and the growth rate of the scale over time. Among other features, the Flowrox Scaling Watch can show the scale thickness, scale profile, growth rates over time, composition, and free flow volume—all of which allow engineers to understand areas where pipes are prone to scaling. The Flowrox Scaling Watch is a predictive device—rather than reactive—and allows its operators to address scale issues before they reach critical levels that can cause downtime or costly damage. “This is completely new technology which has very little competition,” said Todd Loudin, President and CEO of North American Operations for Flowrox. “The Flowrox Scaling Watch can model mathematically the scale build-up and also provide calculations on the free available pipe remaining.”

ncluded in Becker Mining South Africa’s extensive range of locally manufactured slurry and solids transfer pumps are submersible Alert Pumpmor Hydro-Solids pumps, designed for optimum efficiency, low maintenance and extended service life in diverse industries, including harsh operating conditions. “These Hydro-Solids pumps (model HTMS) which are manufactured to stringent OEM specifications, are designed to handle large, stringy and abrasive solids in tough environments,” says Gavin Swart, Becker Mining South Africa. “Alert Pumpmor HS pumps are used in many applications on the mines, including carbon transfer. The open vane design of this range ensures reduced carbon breakage, compared with rubber lined, closed vane conventional pumps. “The heavy duty design of the wet end of these pumps also increases service life, with minimal maintenance requirements. These pumps also offer substantial power consumption savings.”

The model HS solids pump, with capacities to 636 m³/h, can offer pressures up to 40m. Due to the recessed, non-clog impeller, solids or fibrous material up to 200mm (Depending on pump size) can enter the suction inlet and be expelled through the pump discharge. There are six pump sizes in the HS range –smaller models handle S.G’s up to 1,1 and larger models handle S.G’s up to 1,5. HS pumps are available with submersible motors designed for efficient operation in hazardous environments. All components are locally manufactured, which means these pumps are readily available and a large stock holding of spares and raw materials ensures quick delivery. Another advantage of the design of these pumps is that the majority of spares are completely interchangeable which reduces inventory management costs and simplifies on-site repairs. Alert Pumpmor pumps are available from Becker Mining South Africa in horizontal end suction, vertical spindle and submersible configurations, in different materials, to suit specific applications in mining and general industry. The company employs a fully integrated ISO quality management system as part of a dedicated design, manufacturing, testing Enquiry no: 30 and repair facility.

When the Phoenix oil tanker, beached on Sheffield Beach a number of years ago, AQS Liquid Transfer supplied 8 Sandpiper S30’s (inset) – which are 3 inch Operated Double Diaphragm Pumps – to empty the Enquiry no: 31 ship of oil.

February / March 2014

PUMPS, VALVES, PIPES & FITTINGS

KZN Industrial & Business News

Pumps for large volume applications N

Pumping it up R olyn Engineering, with its Head Office in Rustenburg and branches across Southern Africa, including Durban, is the sole agent for ADCA Steam Equipment for south and east Africa. ADCA Steam Equipment in Portugal, manufacture high quality steam traps, control valves, pressure reducing valves and other steam related products for industry. Amongst their products they manufacture a Pressure Operated Pump. This is a carbon steel pump which is recommended in the transfer of high-temperature liquids such as condensate, oils and other liquids to a higher elevation pressure. The pump starts when there is something to pump and stops when there isn’t. Under certain conditions, it can drain a closed vessel under vacuum or pressure. The pump can be operated by steam, compressed air or gas and can be used for lifting any kind of non corrosive liquids. Liquid flows by gravity into the pump through an inlet check valve lifting a float which, at the upper limit of its travel, opens the supply valve allowing steam or compressed air to

enter the pump body. Pressure in the pump builds up only sufficiently to overcome back pressure. The pressurised liquid opens the outlet check valve and discharge commences. When the float reaches the minimum lower level it closes the steam or compressed air supply valve and opens the vent, allowing the liquid to fill the pump again. As the amount of liquid discharged at each stroke is known, the total volume passed during a given period can be calculated by counting the number of strokes during that period. For this purpose a special counter is available which screws into a tapped connection on the top cover of the pump. This counter records the number of pumping strokes thus enabling the pump to function as a reliable flow meter. In May this year, Rolyn Engineering will be celebrating 40 years in business. Enquiry no: 32

ew Germany based Pumpserve holds the sole agency in KZN for the Global Pump range. The Standard TAP (Trash Auto Prime) series of pumps are designed for handling large volumes of water and waste with solids. The pumps range in sizes from 4” to 18” with flows of 1500 to 45,000 LPM. They are also capable of handling solids up to 4-1/2”. Practical applications include, but are not limited to, sewer bypass and liquid transfer. Global Pump also offers a high pressure trash auto prime series (GHT). While maintaining the solids handling capability of the standard trash auto prime, higher heads can be attained with the GHT. The Standard TAP series of pumps are centrifugal trash pumps driven by diesel or electric engines. The pumps are automatic priming because they utilize an engine driven compressor that forces air through a venturi system to creates a vacuum on the suction side of the pump end. This suction allows for continuous priming and re-priming at suction lifts up to thirty vertical feet. The pumps can be used in conditions that cause intermittent flow due to a unique glycol quench system that provides constant

lubrication to the mechanical seal. The pump chassis are available in skid or highway legal trailer formats. A sound absorbent acoustic enclosure is also available for pumps used in noise sensitive areas. The pumps have integrated fuel/chassis tanks that allow for continuous running for over 24 hours. The HAP (Highpressure Auto Prime) series of pumps are designed to handle large volumes of water at high pressures. The pumps range in sizes from 4” to 12” with flows of 2850 to 21,000 LPM. They are also capable of generating up to 100 meter of total head in the standard line, and up to 180m+ with the hyper head series (GHH)

Practical applications include, but are not limited to, dewatering, jetting, fire. Enquiry no: 34

Vertical multistage centrifugal pumps

EO’s LVR (S) vertical multiL stage centrifugal pumps from Raptech are compact, highly effi-

cient, have a low noise operation and are easy to use and maintain. They are designed for transferring low viscosity, non- inflammable and non-explosive liquids with no solid or fibre content. The LVR (S) range is suitable for use in liquid temperatures from -20°C to +120°C and in a flow range from 0.7 – 85 m3 /h. The pumps have a pH range from 3 – 9 and operate with a 33 bar maximum pressure in altitudes up to 1 000 m. The motor is totally enclosed and fan cooled and meets IP55 requirements.

The company plays an important role in many critical fields such as civil water supply, agricultural irrigation, industrial water treatment, heating ventilation engineering, power station construction, petrochemical engineering, mining and more. LEO pumps are sold in over 140 countries and regions worldwide. LEO has grown into the largest smallsized water pump manufacturer Enquiry no: 33 in China.

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

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February / March 2014

PUMPS, VALVES, PIPES & FITTINGS

hile many South African plants are still running on Warman AH series slurry pumps for highly abrasive mill duties, an increasing number of plant operators in other parts of Africa are recognising that the latest generation Warman MCR rubberlined centrifugal slurry pump from Weir Minerals Africa offers superior safety and low ownership costs, as well as outstanding performance and reliability. “These pumps are recording major successes globally across a broad range of commodities and in Africa we’re looking at a number of additional new MCR pumps going into operation this year alone, so this technology is clearly generating a substantial amount of market confidence,” Rui Gomes, product manager: slurry pumps at Weir Minerals Africa, says. “The MCR pump is specifically designed for mill discharge and cyclone feed duties, incorporating a

KZN Industrial & Business News

Mill pumps successes

number of elements that maximise performance in the most aggressive wear applications. Features such as impeller design, liner material, specific speed and bearing assembly allow the pump to easily manage large size particles in dense abrasive slurries and offer the right combination of ruggedness, durability, hydraulics and materials. “A big advantage is the full front throat bush adjustment that helps with pump efficiency and performance and is critical to the efficient operation of the pump, while a quick-change feature allows technicians to replace the wet end of the pump on site.” One of the most outstanding Warman MCR case studies was recently documented at a gold mine in south-western Ghana, where a trial installation was initiated to match the performance and wear life of an existing Warman 14/12 AH metal pump and a competitor’s16/14 primary mill discharge

pump. The trial also sought to determine whether a Warman 350MCR could handle the mill’s tonnage. “The initial milestone of matching or improving on the 2100 tph achieved by the original pumps was quickly achieved,” Gomes says. “The second and more critical goal was to increase the wear life of the pumps and here the target of 1000 hours of operation without failure was also achieved. The impeller lasted about 1900 hours before requiring replacement and the R55 rubber liners continued without needing replacement. “A number of factors drove the success of this trial. Firstly, the pump design was ideally suited to the duty, compared to the pumps previously installed —notably the contribution of the MCR’s rubber lining to the substantial increase in its wear life and the consequent improved mill availability. We were actually astounded at the performance of the rubber liners versus the metal volute originally in place. “At the four month inspection there was still a substantial amount of residual value on the liners and we estimate getting to about 6000 hours — six times as long as the life of the metal volute.” In another successful installation in the West African gold industry, a Warman 350MCR was installed to compare against a Warman 16/14 AH metal pump. The mill was operating at flows of about 2000 m³ per hour to a head of 38 metres and the Weir Minerals Africa team had to install the MCR

to fit in with existing pipework and foundations. The complete wet end was changed out after about 1400 hours, which more than doubled the life of the metal volute of the 16/14, effectively improving plant availability. “This particular site was experiencing the fairly common problem of mill balls coming through the system and cracking the metal volutes,” he says. “However, the R55 rubber liner offered an indirect, but immediate solution to this operational issue. The customer was also impressed by the quick and easy adjustment capability, the reduced cost of replacement spares and the improved safety levels. This MCR was installed in 2012 and we’re getting similar feedback after 18 months of operation.” On the back of the other two success stories, a third gold mine in West Africa agreed to trial an MCR pump against its existing 14/12 AH pump and a full technical team from Weir Minerals Africa designed, supplied and fitted a retrofit base.

This plant was poised to increase its tonnage to 3000 m³ per hour to a head of 39 metres to boost output. “The throatbush ran for about 2000 hours —far more than what was being achieved with the 14/12 metal throatbush,” says Gomes. “Both the impeller and the liners were intact and are still running at the moment, after about 3000 hours without replacement. “The burgeoning interest in our MCR pumps is primarily driven by the improved Total Cost of Ownership (TCO) being achieved. Beyond the gold sector, we’ve also experienced positive spinoffsfrom greenfields projects in Central Africa, Zambia and the DRC. “Most recently, the project house managing a recently commissioned greenfields copper plant expansionin the DRC opted for MCR pumps based on the increasing number of impressive case studies being recordedforthis particular pump. “In terms of brownfields applications, over the years tonnages and requirements change but the pumps very rarely change. This could be detrimental if the pump becomes too big for the duty, impacting on efficiencies and pump life, or too small, affecting wear life. We’ve now proved that we’re able to retrofit MCR pumps into existing piping and foundations to achievesignificant improvements with little or no downtime and we’ve started to focus on a variety of commodity plants where there is pressure to drive costs down and improve processes,” Gomes concludes. Enquiry no: 35

Pinch valve range extended

MG’s Fluid Power division has extended its range of FPV valves to now include new open frame pinch valves, designed for enhanced operating efficiency and extended service life in diverse sectors. These valves, which were launched in August 2013, are particularly well suited for the control and isolation of abrasive slurries on the mines. “These new open frame pinch valves, which have been developed on the successful design of OMSA’s patented FPV diaphragm valves, can also be fitted with replaceable polyurethane lined rubber sleeves as an option, which replace conventional rubber sleeves. “This sleeve design increases the life span of the valve due to the high abrasion resistance of the polyurethane lining,” says Wayne Holton, BMG’s Fluid Power Division. “Pinch valves – with a design where the sleeve is pinched to close mechanically or automatically by fluid pressure in the body - are ideal for controlling the flow of liquids, powders, solids and abrasives.” These pinch valves are available with a short and long frame design, in sizes between DN50 and DN500, with special face to face dimensions and larger sizes on request. The body is made from cast steel, but stainless steel is also available for specific applications. These valves have manual, pneumatic and hydraulic actuation. FPV diaphragm and pinch valves, which are 100% locally manufactured, are available in many different materials, with various pressure ratings to meet exact requirements. BMG’s extensive range of quality branded valves includes resilient seated gate valves, butterfly valves and ball type check valves. Also in the range are knife gate valves, thermoplastic valves and angle seat valves. Key to BMG’s portfolio are FPV diaphragm, wedge gate and pinch valves. BMG supports its extensive range of industrial valves with a technical support service to ensure optimum efficiency and extended service life of every valve. The company also offers a total process and lubrication management solution, to meet exact market demand. Enquiry no: 36

February / March 2014

KZN Industrial & Business News

PUMPS, VALVES, PIPES & FITTINGS

Putting personnel safety first

etback Contracts takes the health and safety of its employees seriously. The recent purchase of welding curtains from Apex Strip Curtains & Doors is a solid demonstration of this commitment. Wetback Contracts has provided southern Africa’s petrochemical, chemical, mining, mineral processing and power generation industries with high quality services since 1975. The company is recognised as one of the leading mechanical and piping contractors in South Africa and has an extensive service portfolio including structural steel, plate work, the fabrication and installation of piping systems, shutdown and maintenance services, pressure vessels, fired heaters and other mechanical equipment. As such, the company spends a large portion of its time welding components and struc-

tures to customised specifications for customers. The company is a member of the South African Institute of Welding and has developed an in-house welding system which captures the details of each and every weld it has completed. “Wetback Contracts stipulated that to protect both its welders and other employees from the hazards associated with welding, it required a welding curtain that would exceed standard safety levels. Apex Strip Curtains & Doors welding and safety screens are constructed from a specially formulated P.V.C. material. This material incorporates a heavy-duty ultra violet light absorber that ensures that dangerous u.v. radiation is safely contained in the curtained off area,” Wim Dessing, managing director at Apex Strip Curtains & Doors, says. All the supplied welding curtains have been

installed on hanging hardware in Wetback Contracts’ new manufacturing facility in Isando, Gauteng. Dessing points out that Apex Strip Curtains & Doors’ reputation is staked on recordable results. “We submitted the welding curtains to extensive testing at the SABS. We firstly measured the level of ultra-violet transmittance. Conventional materials provided readings of 0,0005%, 0,008% and 5.0%, while the Apex product readings were 0,005%, 0,001 and 0,005%. “The SABS also measured the total visible light transmitted through the material. The conventional material allowed 78% transmittance, while the Apex material allowed only 15,5% light transmittance.” In addition to these superior characteristics, the material used in the manufacture of the Apex welding curtains is impervious to burning even when it comes into contact with welding splatter. “Safety remains the underlying objective of the design of the welding curtains and extensive research and testing has resulted in a superior material that offers employees maximised defence against both light transmittance and welding splatter,” Dessing says. “There is no doubt that the inclusion of the Apex welding curtains at Wetback Contracts’ new facilities will result in higher levels of productivity due to the provision of a safer and more comfortable working environment,” Dessing concludes. Enquiry no: 37

RHOKANA ENGINEERING

Technowrap™ is a fully engineered, guaranteed & proven composite repair system providing both short term and long life time repairs. Addressing your internal erosion, external corrosion and thorough wall defects. Pressure in excess of 100 bar. Temperatures up to 220˚C

Technowrap™ repairs are validated to international standards: ISO TS 24817 and ASME PPC -2-2006 Email: keith@rhokana.co.za Website: www.rhokana.co.za Office Number: 031-5614722

Submersible option in demand

ubmersible pump sales to mines worldwide are increasing at the expense of alternative designs because of the advantages of space saving, ease of installation (no pump house required), the elimination of the need to prime the pumps, and savings. Among the submersible pump options available locally is the horizontally mounted model SV submersible pump from the EIM Electric Company of Japan. Sold and supported in South Africa by Mather+Platt, the SV is a horizontally mounted, submersible vortex pump with the advantages of high efficiency, heavy construction for long service life, low maintenance and an impeller that resists clogging. An operational duty equivalent to a standard centrifugal machine makes the EIM SV suitable for transferring

fines, coal chip slurries and similar media, while the pump’s non-clogging vortex impeller ensures that solids travel through the vortex passage rather than through the impeller, increasing the impeller’s wear life. Double mechanical seals protect the motor from the slurry being pumped. The pumps are explosion proofed for mining applications, and are suit-

Phase rotation protection

t is frequently necessary to ensure that motors do not turn in the incorrect direction. In some cases doing so can result in enormous damage to equipment and inconvenience. Think of pumps, compressors and fans. In order to prevent such occurrences some models in the NewElec motor protection range feature this protection benefit as part of other features. Phase rotation protection is available with the NewELec MA, the entire ‘K’ range and the latest NewCode motor protection and control relays. It is important to note that all such products detect phase reversal conditions from the supply side of the circuit. When encountered, the motor is not permitted to start and an appropriate latching and warning LED is lit up on the relay control panel. The NewCode relay offers the technician the ability to ‘fix’ the rotation by incorporating a software solution – no longer necessitating a physical Enquiry no: 39 hard-wire fix.

able for environments up to 40 deg C. Technical specifications include a power rating of 5,5kW to 22kW, a total head from 10m to 20m, a discharge of between 0,9 and 2,0m3/min, and a voltage from 200V to 1100V. The EIM Electric Company is a Japanese firm that has specialised in the manufacture of pumps, motors and related equipment for 60 years. Its range of general purpose mining submersibles include general drainage pumps, super high-head pumps, and vertical and horizontal sand pumps. Pumps for mining applications are flame-proofed, with full stainless steel construction offered as an option. Mather+Platt holds stock of SV pumps and spares. Enquiry no: 38

Tel: +27 31 701 3261/2

Fax: +27 31 701 8216

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

Gardner Denver NASH liquid ring vacuum pumps taking on the Sugar Industry.

Vac-Cent Services (Pty) Ltd licensee manufacturers of Gardner Denver NASH liquid ring Vacuum pumps and Compressors in South Africa, servicing the Southern African market. Specialist services include repairs and testing all types of Liquid ring vacuum pumps for the Paper, Mining, Sugar, Chemical, Food & Beverage and General process industries.

100% locally manufactured www.vaccent.co.za ~ 0861 VACUUM

The Vectra XL single stage vacuum pump is ideal for evaporators with vacuum levels down to 34 mBar

Wadeville 124 Snapper rd, Wadeville, (T) +27 11 827 1536, (F) +27 11 827 3590 Durban 6 Joseph Ave, Durban North, (T) +27 31 572 4495, (F) +27 31 572 4535

February / March 2014

PUMPS, VALVES, PIPES & FITTINGS

KZN Industrial & Business News

Spares contract for giant pumps

PUMP PERFORMANCE AT ITS PEAK! • Lower cost of ownership • Higher productivity • Increased uptime

MasoSine

Flexicon

Apex

Qdos

Peristaltic Pumps

Watson-Marlow Bredel SA provides a wide variety of industrial pumping solutions.

different hose elements to double or triple the flow without investing in a new pump.

MasoSine pumps combine no shear with high suction lift and are ideal for applications in the food processing industry.

Compact Flexicon PF22 peristaltic filling machines offer fast, aseptic filling for pharmaceutical, diagnostic and laboratory applications.

The Qdos 30 range eliminates ancillary equipment, enhances productivity and reduces chemical waste through more accurate, linear and repeatable metering. The APEX range of pumps offers levels of versatility unrivalled by any other positive displacement pump. Its unique geometry allows easy field conversion between three JOHANNESBURG: Tel: +27 11 796-2960 DURBAN: Tel: + 27 31 512-5122 CAPE TOWN: Tel: + 27 21 852-3649 RUSTENBURG: Tel: + 27 14 596-6695 E-mail: info@wmbpumps.co.za Website: www.watson-marlow.com

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Peristaltic Pumps meet virtually any capacity and controlled requirement with options of fixed or variable speed, digital, analogue or manual control, and single or multi-channel flows. Flow rates vary from microlitres a minute to tens of thousands of litres an hour.

Watson-Marlow \ Bredel \ Alitea \ Flexicon \ MasoSine

he Government of Iraq has ordered spares worth R5-million for five super-pumps it bought from a South African engineering company eight years ago. Designed and manufactured by Wadeville-based APE Pumps in 2005, each of the giant 1600mm single-stage vertical turbine machines weighed 17 tons as it left the Wadeville factory, and 36 tons after fitting with a 1300kW electric motor. With duties of 4000 litres per second at heads of 20 metres, these pumps remain the biggest that APE Pumps has yet built. All five were installed during refurbishment of a pump house at a dam 200 kilometres north of Basra in south-east Iraq, where they have run faultlessly for eight years. One of the constraints overcome by APE’s engineers during design of the original machines was the need to fit the pumps within existing sumps, and align the units to existing pipework. Fabrication was altered to meet this requirement, and special bases constructed to fit existing foundations The pumps were made of standard materials throughout, with cast iron

bowls and stainless steel shafts and impellers. Commenting late last year on the spares order, APE Pumps director Alan Sternsdorf said that the eightyear period over which the pumps had been running was testament to their reliability, as the water from the river contained a lot of sand and other

impurities. “We will present the spares for inspection by an independent third party for verification as OEM parts. Authorities from the Iraqi embassy in Pretoria will attend this inspection, on completion of which the shipment will leave by road for the port of Durban,” Enquiry no: 40 he said.

Piping systems for the harshest environments

s a leading provider of piping system solutions, GF Piping Systems carries over 60,000 products for the safe and reliable transport of liquids and gases. State-of-the-art jointing technologies, fittings, valves, automation products and pipes are used in a wide range of applications from the water source to the point of consumption. For example, over one billion cemented joints using PVC-U from GF Piping Systems have been installed in thousands of applications in water treatment, chemical processing, energy generation and ship building. GF Piping Systems offers integrated system solutions in many different plastics, from weldable pipes and fittings up to a diverse valve range with many connection options.

2014/02/04 12:38 PM

Covering all requirements of the most significant international standards proves the quality and safety of the systems. GF Piping customers can be assured that the polyethylene and polypropylene systems guarantee a maximum of safety, reliability and performance – the ideal choice for any challenging application on the industrial field. GF Piping Systems offers a unique service, customizing products to the applications’ needs and expert product Enquiry no: 41 advice.

February / March 2014

KZN Industrial & Business News

FORESTRY, PULP & PAPER

A growing business in the making

wattle and pine plantation owned by a community trust following a successful land restitution claim is growing from strength to strength. The Izanqawe Community Trust took ownership of the land, previously owned by private farmers, in 2007, after it was bought by government and handed back to the dispossessed community. The farm is situated in the hills east of Greytown in the KZN Midlands. Despite the promise of government funding through discretionary grants and/or recap and development grants, there has been no money forthcoming from government to help the community to get the farm up and running, baring money to purchase a tractor and trailer coming from the DAFF. However, the Trust, led by Chairperson Thokozani Zondi and Secretary Patrick Dlamini, and with considerable help from neighbours and other stakeholders, has man-

aged to keep a timber business going and in the process won the prestigious 2013 NVT Tree Farmer of the Year award (farming on communal land). Neither Thokozani nor Patrick are trained foresters. In fact, Thokozani is Principle of Lukazi Primary School in Estcourt and Patrick is the admin clerk at Siphakeme Combined School in the nearby Tugela valley, so they are only able to devote holidays and weekends to the farm. However they both grew up in the timber growing KZN Midlands area and so they are not completely new to forestry. “When we took ownership of the land in 2007 we realized that there was an opportunity to carry on with tree farming, but we had nothing. We met with Martin Hill of Bracken Timber, our neighbor, and he agreed to help us. He loaned us a tractor and trailer so we could get going. The first year we felled some wattle and managed to make some money and were able to pay our employees,” said Thokozani. Some 200ha of wattle and 35ha pine in a sawlog rotation was already established on the farm when the community took over. Today the trust employs 24 people working under ‘induna’ Ncamisile Zulu. The team does silviculture and general maintenance work on the farm, has been clearing wattle jungles as well as harvesting wattle for pulp and bark. All timber cleared and harvested is utilized by the community or sold. Wattle pulp is sold through NCT while the bark is sold to NTE. Bracken assists with the burning of fire breaks, does pine thinning and high pruning, and harvests and purchases the sawlogs for their sawmill. The SANBI Grasslands Programme, which has been engaging with small growers in a bid to improve land use practices and conserve high conservation value grasslands, came on board and deployed an experienced forester, Gilbert Plant, to assist and mentor the Izanqawe Trust. The Grasslands programme team is collaborating with NVT in a bid to facilitate FSC certification for small growers, including Izanqawe Trust under NVT’s group scheme. This, explains the

New CEO for paper giant

he board of directors of Sappi T Limited has announced that Steve Binnie, currently the Chief Financial

Officer “CFO” of the company, will succeed Ralph Boëttger as CEO on 01 July 2014. Steve Binnie (46) joined Sappi on 09 July 2012 as CFO-designate and became CFO and joined the Sappi Limited Board on 01 September 2012. Prior to joining Sappi Steve had been the CFO of Edcon (Pty) Ltd since 2002. Prior to joining Edcon he was Group Financial Manager at Investec Bank Limited and held senior management positions at Transunion ITC and New

Zealand Milk Products (SA). He is a Chartered Account and holds an MBA from Heriot-Watt University, Edinburgh, Scotland. Dr Danie Cronjé, Chairman of the board of Sappi Limited, said: “I would like to congratulate Steve on his appointment. The board believes that Steve has all the necessary skills and attributes to take Sappi forward and to deliver strong growth into the future. “It is anticipated that a successor for the role of CFO will be announced Enquiry no: 42 before the end of June 2014.”

Grassland Programme’s Steve Germishuizen, ties in with their aim of promoting better land use management, thereby contributing to the conservation of threatened natural grasslands. The Grasslands Programme team has brought Ezemvelo KZN Wildlife in to assess the grasslands on the farm, and they have recommended the establishment of a protected area incorporating the grasslands and game reserve areas, creating exciting ecotourism opportunities. Gilbert Plant acts as mentor to the Trust and meets with Thokozani and Patrick regularly. He assists with planning and budgeting, provides advice and guidance on maintenance of open areas, roads, silviculture, and fire protec-

tion, compartment planning, harvesting and marketing of timber. Following the successful claim of another timber farm nearby, the total landholding of the Izanqawe Trust is around 8 000ha. This farm includes 850ha of pine and a sawmill. Thokozani said they had agreed that the former owner would continue to run the operation for at least a year until the Trust is ready to take it over. In addition to the Timber business, the Trust is exploring opportunities to grow cash crops, raise livestock and operate a game farm. Courtesy: SA Forestry Magazine www.saforestrymagazine.co.za Enquiry no: 41

February / March 2014

FORESTRY, PULP & PAPER

KZN Industrial & Business News

NCT rolls out PBS vehicles

Get tough jobs off the ground Telescopic Tool Carriers • Two and Three Stage Boom • Impressive Lifting Capacity • Unmatched Steering • Hydrostatic Transmission • Extendable, Low-Profile Boom

New Generation PBS vehicles

• Enhanced Cooling System • Lateral Operator Restraint System • Frame Leveling • Turbo-Charged Diesel Engine • Quick-Tach Mounting System

M500 Skid-steer loader • Improved visibility for precise work and enhanced views • Better digging, pushing and attachment power that boosts performance • Reduced sound levels by more than 60% • Efficient, higher-capacity cooling for longer engine life

Sales Service Rental Call any of our branches nationwide on: 010 593 6916 • bobcat@goscor.co.za www.bobcatasa.co.za A proud member of the Goscor Group of Companies

picture courtesy: Garden City (Commercial) – Pietermaritzburg

CT, Zabalaza Hauliers, with the support of the KZN Department of Transport (DoT) have designed a new generation of PBS vehicles. These vehicles are the culmination of extensive research and development, including comprehensive simulation exercises which were performed in Australia, where the PBS concept originates. PBS refers to performance based standards. The traditional approach to heavy truck and trailer design is that prescriptive legislation sets mass (GCM<56 tons) and dimensional limitations (max length 22 meters). PBS vehicles are evaluated against a defined set of standards to ensure road safety and infrastructure protection, thereby making it possible to increase the payload without increasing the impacts on the roads, infrastructure and other road users. The ultimate objective is to improve payload efficiency. The key difference between the NCT/ Zabalaza vehicles and previous generation PBS vehicles developed in SA is that they are shorter, with an overall length of just 23.1 meters. They are compact which makes them more versatile and can travel on more routes than the longer vehicles of 24m. The vehicles carry a payload of 49-50 tons vs. a standard timber truck payload of 38-39 tons. This translates into a saving of 10% 15% of the R/ton transport rate if compared to a standard timber truck. The PBS vehicles are based on a 6 x 4 design with a single axle in front and a fiveaxle drawbar trailer, manufactured by Afrit. The trucks are Mercedes Benz Actros 3350s. The timber industry has been at the forefront of the development of PBS vehicles in

PARTS FOR ALL MAKES OF CRANES AND HOISTS FROM

South Africa. Sappi and Mondi were the pioneers who put the first PBS vehicles on the road. NCT adopted a cautious approach and first evaluated the original PBS vehicles before developing its own PBS capacity, which currently haul timber from the KZN Midlands to NCT Durban Wood Chips, Bayfibre and ShinCel in Richards Bay. Strict conditions for operation of PBS vehicles are required in terms of the DoT permit. The transport operator must be RTMS accredited, which means the company adheres to high standards of safety, driver training and wellness, vehicle maintenance and record keeping etc. The vehicle can only be operated on approved roads, ranging from district roads to national highways and the transport operator must report to the DoT on a monthly basis on routes and performance. NCT currently brokers the movement by road of some 700 000 tons of timber a year, and is keen to increase the number of PBS vehicles for a number of reasons: The cost of transport has steadily increased, while the price of timber has remained static. The PBS vehicles represent a 10%-15% reduction in the cost per ton of timber transported, which puts more money back into farmer’s pockets. PBS vehicles carry a 24% bigger payload than standard timber trucks; their use reduces the number of truck trips on our country’s roads – a win-win for farmers, for the environment and for other road users Courtesy: NCT Forestry Enquiry no: 43

New maximum duty knife gate valve for abrasive, cyclone services

These are just a few of more than 100 Crane and Hoist brands owned by Konecranes. Konecranes has more than 420000 Cranes under Service Contract globally where the majority are not Konecranes and but competitive brands . All of which gives Konecranes the ability and considerable purchasing power to supply parts for all makes of cranes competitively. Tel +27.11 581 6600 or 031 701 4881 Parts.ZA@konecranes.com www.konecranes.co.za

Johannesburg - Durban - Cape Town - Port Elisabeth - Witbank - Klerksdorp

eZURIK recently announced the availability of the new KGCMD Maximum Duty Cast Knife Gate Valve. These Maximum Duty Knife Gate Valves are specifically designed to provide the shearing and sealing capabilities needed in demanding services such as cyclone separators, recycle high density cleaners, recycle detrashers, or sand cleaners. Because the valve is designed to provide long service life in highly abrasive applications, it can be used in many applications in the Pulp and Paper, Mining, Chemical, Petrochemical, Power, Steel and Food Processing industries. The KGC-MD Knife Gate Valves are available in 3-24” (80-600mm) sizes with metal or dual metal and resilient seats. To withstand highly abrasive media, the valves are available with a replaceable hardened seat, hardened gate, full 100% port opening, high performance packing system with wire scraper rings, and heavy-duty superstructure. All these features combine to provide a longer service life, less downtime and less maintenance than other valves designed for these tough applications. Enquiry no: 44

February / March 2014

FORESTRY, PULP & PAPER

KZN Industrial & Business News

The art of paper making

Minimising waste and adding value: Lignosulphonates at Tugela Mill

oncrete is currently the most used man-made material in the world, with three tons used annually per capita. Population growth and urbanisation are expected to lead to hundreds of millions of people moving into expanding urban centres, primarily in Asia and Africa. This in turn is expected to lead to increasing demand for sustainable building and infrastructure works. These trends mean that the opportunities for the sales and marketing of lignosulphonates, an important raw material in concrete admixtures, will increasingly expand over time. Lignin is removed from wood in the pulping process. The Sulphite pulping process – such as the one used at the Sappi Tugela mill converts the lignin to a sulphonated state, otherwise known as Lignosulphonate. This co-product from the digester cook is recovered from the pulping process and processed into a final product to act as dispersant when wet and binder when applied and dried; and consequently has a wide variety of applications. They are a very effective and economical adhesive, acting as a binding agent or ‘glue’ in pellets or compressed materials. They

can, for example, be used on unpaved roads to stabilise the road surface. Lignosulphonates prevent the clumping and settling of undissolved particles in suspensions. By attaching to the particle surface, they keep the particle from being attracted to other particles and reduce the amount of water needed to use the product effectively. This dispersing property makes lignosulphonate useful as a dispersing agent in concrete mixes. Lignosulphonates from the mill are sold to concrete admixture manufacturers for use in their admixture formulations allowing concrete to be prepared using less water (giving stronger concrete) while maintaining and improving the ability of the concrete to flow. Lignosulphonates from Tugela Mill are also sold to customers for use in a dust suppressant product for the mining industry. This product reduces environmental concerns related to airborne dust particles and also reduces water usage (the conventional method of dust suppression is to use only water). The customer reports that whereas previously excessive dust caused considerable downtime during night shifts, the increased effectiveness of the dust suppression product has meant that most mines supplied have increased their output during night shifts. The binding quality of lignosulphonates makes them useful in a variety of applications, including fertiliser, briquette and animal feed binders and as a binder in gypsum board. The mill is currently selling a small amount of lignosulphonates to the fertiliser industry and is examining the potential of other applications.

Enquiry no: 45

hirty years ago paper machines were running at a speed of 800 m/mi. Since then considerable innovations and improvements have resulted in machines that run at speeds of up to 2200 to 2500 m/min. Given this, without a well designed, effective and reliable trim and waste removal system the various reeling/ rewinding machines cannot run efficiently 24/7, which means that a trim removal system must be capable of

extracting and removing about 5500 kg of paper trim per hour. An effective trim extraction system has to start at the slitters/re-winder and at this point, a well designed extraction hood conforming to the natural trajectory of the trim is crucial. From there the trim is conveyed via a suitable duct system to the chopper fan, where it is cut into pieces. At this point, an air volume regulator is necessary in front of the chopper fan inlet to adjust the air flow from the extraction hood to coincide with the speed of the machine in order not to tear the paper strip at lower machine speeds. Along from the chopper fan there will be an air/trim separator, which separates the trim from the air stream. From the air separator the trim pieces can be discharged directly into a pulper or alternatively in to a baler. The separator air discharge is usually connected to a bag filter which

removes and collects the fine dust particles from the air stream. AES manufactures and installs these systems - with the backing of their Italian principals New AERODINAMICA - who provide the technical support and the supply specialized equipment such as chopper fans, air separators, air volume regulation nozzle etc. New AERODINAMICA is well known to the paper, card board and packaging industry in Europe. AES is therefore well equipped to handle the problems associated with the effective removal of all trim and waste from slitters/re-winders and die cutting machines Apart from paper trim extraction and collection systems AES also designs and installs dust extraction systems, industrial ventilation/filtration systems, central vacuum cleaning systems as well as pneumatic conveying systems. Enquiry no: 46

Trusted screen media solutions since 1905 No matter what your screen media requirements, FLSmidth offers the most comprehensive and innovative range of screen surface media in the industry! Our field-proven and time-tested Meshcape brand has dominated the South African market since 1905 and continues to increase in international popularity since joining the FLSmidth family of brands back in 2012. We offer a full line of standard, modular and customizable screen media including woven wire screens, KASON (Sweco) machines and spares, expanded metal, perforated materials, polyurethane products, wedge wire, welded mesh and wire conveyor belts. If you’re looking for durability, versatility and superior product performance in media recovery, then look to Meschape branded screen media from FLSmidth. For more information, visit us at www.flsmidth.com Within South Africa 0861 00 6374 • Edenvale +27 (0)10 210 5000 Cape Town Branch +27 (0) 210 5100 • Durban Branch +27 (0) 210 5125 PE Branch+27 (0) 210 5175 • Kimberly Branch +27 (0) 861 00 6374

February / March 2014

FORESTRY, PULP & PAPER

KZN Industrial & Business News

Going green? Paper is the way to go

e are told to ‘save the planet and go digital’ or save the environment by opting for e-billing. You may even have ‘please consider the environment…’ on your emails. The Paper Manufacturers Association of South Africa (PAMSA) highlights the environmental benefits of paper and print, and encourages people not to buy into claims that going paperless saves trees and combats climate change.

Both sides of the story “We live in the digital age – an age of convenience and accessibility. But these benefits should

not be promoted as ‘greener’ than print,” says PAMSA’s Jane Molony. Paper is produced from a renewable resource – wood. It does not come from indigenous forests but from sustainably managed timber plantations. All paper produced in South Africa comes from plantation-grown trees, recycled paper or sugar cane. Around 600 million trees across 762,000ha are specifically farmed for pulp and paper manufacturing. These act as massive carbon sinks, absorbing millions of tons of carbon dioxide. When timber is harvested and turned into pulp and paper, the carbon stored is only released when the paper

burns or biodegrades. (This is why we should recycle paper – to keep the carbon stored for longer.)

The darker side of digital In his report Print vs Digital Media: False Dilemmas and Forced Choices, Don Carli, a senior researcher at the Institute of Sustainable Communication, says: “While paper mills emit visible plumes of steam, and waste paper piles up in plain sight, the invisible ‘grey energy’ used to manufacture digital technologies and the toxic ‘e-waste’ associated with electronics are largely out of sight and out of mind. ‘Dark data’ is also exchanged between computers but never seen

by human eyes.” The average American consumes almost 34 gigabytes of data daily, mostly invisible ‘dark data’, the impact of which researchers are just beginning to study. “We don’t know the environmental impact of saving a document on a server for 10 years or more. And we have no idea of the impact of extracting finite resources to make electronic devices that cannot easily be recycled safely and practically,” says Hans Wegner, chief sustainability officer of the National Geographic Society. Notably, Greenpeace has identified electronic waste as the fastest growing component of the municipal waste steam.

The bigger picture “We need to look at the life cycle of the products we use – whether paper or digital,” stresses Molony. “Environmentally conscious citizens who use digital media would need to consider raw materials, how and where items are manufactured, their means of transportation, how they are powered and their recyclability.” In considering sourcing paper products and printed material, the simplest way is to buy locally produced paper

or look for certification symbols (FSC, PEFC or SFI) which demonstrate a sustainable process, from the forest to the consumer. Consumers often fall into the trap of insisting on printing on recycled paper. “Most recycled paper is imported along with a hidden carbon footprint. FSCcertified virgin paper is just as green, and you support the local economy.” Carli sums it up: digital media doesn’t grow on trees. For more information or to download (and print) a fact sheet, visit www.thepaperstory.co.za and follow @PaperRocks_SA on Twitter.

FAST FACTS

• Approximately 150,000 people are employed because we use and recycle paper products. • SA consumed 2.6 million tons of paper, corrugated materials, board and tissue in 2012. (Of this, 864,000 tons were imported.) • Of the 2.4 million tons manufactured locally, 605,000 tons were exported. • Some 1,151,315 tons of paper and board was recovered for recycling in 2012. Enquiry no: 46

What’s in a box? Tailormade packaging solutions

f you were to visit a fresh produce market in Europe and you admire the abundance of fresh, juicy fruit on display, you are bound to find some of the very best produce having come all the way from South Africa. Our country is renowned for exporting some of the best fruit – whether it’s deciduous, citrus or grapes. Fruit exporters in South Africa know the importance of getting their produce to the markets in a fresh, unbruised and presentable manner. Celebrating its Diamond Jubilee this year is the Sappi Tugela mill, based in Mandeni on the KwaZulu-Natal North coast. The mill produces a range of high quality semi-chemical fluting and recycled container boards manufactured from Recycled and Virgin Fibre. These products, combined with others made within the Sappi family at our sister mills, produce tailor-made packaging solutions for various applications. Hi-Yield Fluting – is manufactured from semi-chemical pulp which imparts superior strength properties.

The differentiation strength properties of Hi-Yield Fluting make it attractive to corrugated case makers for use in a variety of end-use applications, ranging from demanding high value industrial packaging to agricultural fruit and vegetable packaging. SuperFlute – our premium virgin fluting, offers superior ring crush properties and superb cyclic humidly resistance properties. It is designed for use in agricultural packaging where the structural integrity of corrugated cases throughout the supply chain, during cold storage, handling, stacking and transportation is critical. Farmers and industrial manufacturers rely on SuperFlute for protection of their valuable cargo. Tugela Liner – is a two-ply linerboard with exceptional stiffness and high ring crush properties and when used in conjunction with Superflute during case making, offers end users innovative packaging solutions for industrial and agricultural applications. Testliner – this product has high recycled fibre content and is also well suited for industrial packaging solutions. Mandeni fluting and liner – produced with 100% recycled fibre used for industrial packaging applications The Sappi Tugela mill produces 200 000 tons of paper Enquiry no: 47 product per year.

PRODUCTS & SOLUTIONS to make the handling of bulk materials CLEANER, SAFER and MORE PRODUCTIVE. Belt Cleaners • Transfer Point Solutions • Air Cannons Vibration • Dust Management • Silo Cleaning

call +27(0)13 656 5135 | visit martin-eng.co.za email service@martin-eng.com

A global company. Est. 1944

February / March 2014

KZN Industrial & Business News

Silo cleaning without confined space entry

Reliable pneumatic products

very high air volumes, often as much as 1,200 CFM. “To achieve that kind of pressure, the

diesel compressor rental alone can be more than R10 000 a day, and the fuel bill for a full day’s work could be half again as much,” he said. “Then there’s the cost to actually do the work.” Potential damage to the storage vessel can also be an issue. Some cleaning technologies use the very high pressure to blow air through a hose that’s simply dropped into an access hole at the top of the vessel. At the end of the hose is a tool with a restricted nozzle, which causes the “cleaning head” to thrash about randomly. While this technique works in large blockages, it provides little or no control, and as the head gets closer to the vessel wall, it has an equal chance of taking out a chunk of the silo as it does hitting material for removal. For extreme blockages where hardened lumps of material have plugged discharge chutes, silo cleaning technicians also use the Martin Buster, which safely dislodges block-

strength

ulk material handlers now have a proven solution for blocked vessels and plugged discharge chutes, one that will remove build-ups, reclaim lost material and restore design capacity and flow rates. In most cases MartinPLUS Silo Cleaning eliminate the need for confined space entry and hazardous cleaning techniques such as explosives, water and air lancing, typically allowing the material to be recaptured and returned to the process stream. Technicians from Martin Engineering use remote-controlled equipment from the top of the vessel to safely address blockages. With nearly 70 years of experience in solving material flow problems, the company employs highly-trained specialists who are safety-certified to current OSHA and MSHA standards. Most cleaning projects are performed with the Martin Heavy Duty Whip, a portable, remote controlled tool that can be lowered into storage vessels through a manhole opening. Powered by compressed air, the Martin Heavy Duty Whip can be equipped with a variety of flails and cutting edges to knock down accumulated material without damaging storage vessels. Abrasion-resistant steel chain is best suited for most applications, with non-sparking brass chain for combustible materials. Urethane flails can also be employed to protect lined vessels that could be susceptible to damage from metal tools. “With this technology, the need for confined space entry is greatly reduced”, observed Martin Engineering Silo Sales Specialist Marty Yepsen. “The equipment can be set up quickly outside the vessel, and it’s portable enough to move easily around various bin sizes and shapes.” The Martin Heavy Duty Whip uses a modular boom arrangement that extends from 2 meters up to 8.5 meters and can clean vessels up to 18 meters in diameter and 68.5 meters tall from a single central opening of just 450 mm. The pneumatic cutting head delivers powerful whip action from the rotating head to remove buildup from walls. The hose reel easily separates from the boom assembly for transportation and set-up in tight spaces. “There are competing systems that utilize hydraulics, but they tend to be heavy and cumbersome,” said Martin Engineering Territory Manager Jim Densberger. “And they present the possibility of a fluid leak, which could contaminate otherwise-salvageable material. The whip requires no hydraulics; it needs just 90 PSI and 100 CFM, which can usually be supplied from a plant’s existing air system.” Some pneumatic cleaning systems require

ages by the powerful force of expanding CO2 gas. The technique employs non-explosive generators that cause rapid gas expansion to fracture chunks and compacted material, opening the discharge and restoring normal flow. When bridged or arched material creates a no-flow condition, technicians can rely on the Martin Drill to bore through tough clogs. The drill’s powerful hydraulic action drives its way through blockages, clearing a pathway at depths up to 45 meters. MartinPLUS Silo Cleaning is provided as a turnkey service. The company’s fully-equipped teams bring all required equipment and personnel directly to customer sites. Many facilities are able to remain in operation during vessel cleaning, but when conditions require a shutdown, technicians work evenings, weekends or holidays to accommodate customer Enquiry no: 48 schedules.

Durable packaging that ticks all the boxes When it comes to meeting today’s stringent demands for a strong paper packaging solution that has the necessary strength, versatility and convertability for use across a range of applications, Sappi Containerboard ticks all the boxes. As an added benefit, Containerboard is made from sustainable, renewable resources and is completely biodegradable. So make the responsible choice.

Choose paper packaging. Choose Containerboard from Sappi. www.sappi.com

owson and Dobson Industrial - a market leading supplier of a comprehensive range of world class industrial products and after sales service solutions - offers a wide range of internationally recognised Waircom pneumatic products to local industries. Waircom was established in Europe in 1957, and now has a presence in over 150 countries worldwide. The company offers a range of pneumatic components aimed at industrial automation, including; cylinders, valves, silencers and flow control systems. Dowson and Dobson director Terry O’Kelly explains: “Dowson and Dobson offers a wide range of Waircom push-in fittings in a variety of sizes and configurations, to meet all pneumatic piping needs. The company also supplies various Waircom pilot and solenoid directional control valves, as well as manual and mechanical directional control valves, foot pedal valves, cylinders, as well as standard profile cylinders (32-100 bore) and external tie rod cylinders from 125mm to 320 mm bore.” The range of pilot and solenoid directional control valves available include the EK series and the MEK series of body parted pilot and solenoid valves. “The EK series of valves are available in various sizes, configurations and voltages. They are robust and trusted in the Enquiry no: 49 industry.

THE TITANIUM ROOM/KZN INDUSTRIAL AND BUSINESS NEWS 1402

FORESTRY, PULP & PAPER

February / March 2014

FORESTRY, PULP & PAPER

Continued growth prompts move

ollowing impressive growth throughout the course of 2013, top liner plate expert Rio-Carb has spent more than R9-million on purchasing a 3000 m2 state-ofthe-art manufacturing facility in Johannesburg. Rio-Carb director Martin Maine notes that the move was made in late 2013, as a result of a significant rise in demand for the company’s innovative range of Chromium Carbide (CrC) liner plates, pipes and welding wire, which are proven to be highly effective in abrasive applications. “Our new factory is located on 4000 m2 stand, and has been specifically redesigned with new facilities in order to provide customers with the excellent quality of product that they have come to expect from Rio-Carb, in substantially reduced turnaround times,” he explains. Among the new additions is a computer aided design (CAD) plasma control centre, which is able to streamline the productivity of the company’s plasma cutting machines, by ensuring more accurate sizing and nesting of liners. Maine reveals that the CAD system can be linked directly to the designer’s CAD system to ensure the highest levels of precision and accuracy. “This means that a chute designer can create a mirror image to the nearest millimetre of the eventual fit of the liners to ensure that the stud and holes mate, and that bolting fits correctly the first time. This reduces the complexities related to onsite assembly, and eliminates challenges further down the line. The plasma centre is operative on a 24/7 basis to cater for breakdown jobs and to eliminate bottlenecks in production. A 5 ton crane assists with rapid assemblies, “ he continues. Another major benefit of the new Rio-Carb factory is the fact that it has been designed with environmental sustainability in mind. Maine says: “Great attention has been paid to reducing CO2 emissions. Bearing this in mind, more than 80 high bay lights with 400 W globes have been replaced with LED equiva-

J lents, which consume just one eighth of the original power.” Maine points out that Rio-Carb has committed itself to making its product line more environmentally friendly too. “Lasting eight to ten times longer than conventional liners, our CrC liner plates have always been more ecofriendly. We have, however, taken this one step further by following internationally recognised ISO 14000 certification for waste disposal and resource conservation.” Looking at the year ahead, Maine indicates that Rio-Carb will be launching a new line of Impact Resistant CrC liner plates, which will benefit the mining sector in particular. “Furthermore, we are currently in the process of developing a new product in our fabrication division. Although it is still in its early stages, I am confident that it will have an overwhelmingly positive effect on the cement industry.” Maine believes that Rio-Carb will continue to achieve measurable growth throughout 2014. “The unprecedented growth experienced by Rio-Carb in the past year can be attributed to the fact that all engineering services are undertaken in-house under one roof, thereby eliminating the risks of substandard work done by outsourced subcontractors. With our advanced new facility, this strength will only improve, and will enable us to expand our less established divisions, such as the fabrication business. With foreign investment continuing to pour into Africa, I am confident that the potential for growth in 2014 is tremendous,” he concludes. Enquiry no: 50

MEET THE FAMILY

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

KZN Industrial & Business News

New boiler for process steam and power generation

ohn thompson, the Cape Town-based designer and manufacturer of industrial boilers and associated plant, with over 75 years of service to South Africa's industries, has developed a new watertube boiler, MicroGen, to cater for the growing demand for a small, medium-pressure, power boiler particularly suited to fibrous-biomass fuel and coal-fired, co-generation applications. The boiler has been designed for a steam output of between 20 and 25 t/h dependent upon fuel type. Higher outputs can be achieved with multiple boilers. In order to match popular steam turbine selections that can achieve good cycle efficiencies at reasonable cost, the boiler can produce steam at pressures between 31 and 61 bar. The design incorporates a single-drum configuration with a membrane-wall furnace construction. In all industries, energy cost has become a major consideration in the management of existing plants and in the feasibility studies for potential new plants. Often, in remote areas or where exorbitant electricity prices from the national grid defeats the feasibility of a plant’s operations, generation of power for own consumption has become a priority. Processes that require steam as the heating medium could have potential for cogeneration. In short, co-generation is where high-pressure steam is used to turn a backpressure turbo-alternator while the exhaust steam is used as process steam. In this way, for a small increase in thermal input, the plant can generate electricity while also generating sufficient heat to meet the requirements of the particular process. If a process produces combustible wasteproducts that can supplement the fuel feedstock, the case for co-generation is made even stronger. Environmentally, the project becomes more attractive and viable if the fuel can be considered a renewable biomass fuel. In addition to coal, a wide variety of biomass fuels can be burnt on the stoker including; bagasse, wood-waste, -pellets, -chips, -pucks, sawdust, sunflower and cotton-seed husks, nut shells, grape pomace pellets, corncobs, dried-hops and torrified biomass. The MicroGen boiler is configured to facilitate manufacture of the pressure-parts in large sub-assemblies which can be containerised for transportation. This will minimise expensive and time consuming site construction work.

The furnace design incorporates; a CAD (continuous ash discharge) stoker, a suitably proportioned furnace and pneumatic fuel spreaders. This configuration can accommodate both suspension-firing of biomass and the combustion of heavier solid fuels on the grate. As thermal efficiency will be crucial for any energy project, the MicroGen boiler will be supplied with a heat recovery tower which includes a tubular air-heater and an extended-surface economiser. Flue-gas clean-up equipment will be supplied to suit the site and/ or customer specific requirements. CFD technology is used to configure the furnace and gas pass dimensions to achieve optimum combustion and heat transfer while minimising the risk of corrosion. John Thompson can also undertake the complete cycle design. This incorporates the heat / mass balance and selection of the appropriate number of MicroGen boilers matched with a back-pressure or extraction condensing turbo-alternator(s). As John Thompson is a division of ACTOM, the largest manufacturer, solution provider, repairer and distributor of electrical equipment in Africa, they can also engineer and install all electrical plant and associated equipment. Although there is not a turbo-alternator in the Group's product portfolio, this can be easily sourced from "the best value for money" supplier. Enquiry no: 51

February / March 2014

KZN Industrial & Business News

POWER GENERATION From left, Prince Moyo GM: Power Delivery Engineering at Eskom; Nigel Blackaby, PennWell Events Director; Dr Willie De Beer, industry expert and Chairman of the DistribuTECH Africa Advisory Board

Africa moves to increase power infrastructure

frica’s power demands are soaring beyond the capacity of an ageing infrastructure to cope, but multiple programmes are being put in place to address the challenges. This is according to Dr Willie de Beer, Chairman of the DistribuTECH Africa Advisory Board. Pretoria based energy expert De Beer was speaking at DistribuTECH International/Utility Products in San Antonio, Texas, where nearly 10,000 delegates from 67 countries gathered to discuss global power trends and challenges last month. He said that Africa’s total power demand in 2010 was 590 TWh, projected to grow to 3100 TWh by 2040 on the back of an everincreasing demand for energy. “The population of Africa is projected to reach 1.9 billion by 2050 and customer expectations are on the increase,” he said. De Beer said that while there were pockets of power excellence and high levels of stability across the continent, the need for investment and upgrades was clear. However, South Africa and the continent as a whole, was taking steps to address the challenges. De Beer noted that Africa is part of the Smart Grid infrastructure investment by 45 emerging market countries – including Brazil, Russia, India, China and South Africa – which over the next decade will reach $274.9 billion, outpacing investment by developed countries. In addition, Africa and South Africa’s investment is particularly focused on reducing electricity theft, improving reliability and incorporating renewable energy into electricity grids, and

Africa is a key focus for the US, benefiting from President Barack Obama’s grant package worth $7 billion in government funding plus an additional $9 billion in private sector commitments. De Beer told delegates: “Eskom, South Africa’s national electricity company and DistribuTECH Africa’s Host Utility & Networking Sponsor, plans to spend over $150 billion on power infrastructure over the 2010-2030 timeframe, including $11 billion on transmission-sector reliability alone and pilot projects over the next 10 years.” Africa’s plans to address power challenges and meet the future demands of an increasingly industrialised continent will come under in-depth discussion at POWERGEN Africa and DistribuTECH Africa in Cape Town in March. These events, co-located for the first time at the Cape Town International Convention Centre from 17 - 19 March 2014, will attract around 3,000 industry experts and power industry professionals from across Africa and abroad. The event, presented by PennWell Events, will feature the best of the international POWERGEN and DistribuTECH events, combined with an in-depth focus on Africa’s unique challenges and opportunities. The world’s leading power engineering vendors will also present solutions designed to address Africa’s unique power challenges. For more information about attending POWER-GEN Africa conference and exhibition, visit www.powergenafrica.com, Enquiry no: 52

KZN Private Sector Energy Efficiency project launched T he National Business Initiative (NBI) together with the EThekwini Municipality launched the KZN Private Sector Energy Efficiency (PSEE) project at the Moses Mabhida Stadium recently, and are calling on business to register their interest in the project. Joanne Yawitch, CEO of the NBI and PSEE project said, “The NBI recognises the significance of energy in relation to cost, security of supply, impacts on competitiveness and carbon emission reduction, and has worked for many years with leading companies and the Department of Energy to support companies in reducing their energy usage. This has resulted in the establishment of Energy Efficiency Leadership Network (EELN), a partnership of over 50 leading companies with government and which calls for the private sector to take action in the continuous improvement of Energy Efficiency.” She announced that the NBI has been awarded £8.6 million by the United Kingdom (UK) Government through its Department for International Development (DFID) to implement a countrywide programme of support to the private sector for Energy Efficiency improvement. The “Private Sector Energy Efficiency” Project (PSEE) aims to improve energy effi-

ciency in commercial and industrial companies in South Africa through the provision of various services to assist companies in identifying and implementing energy saving measures. /the project which comes under the UK-SA Bilateral relationship will contribute to the South African government’s strategy for reducing energy demand. The PSEE Project is governed by a multi-stakeholder Steering Committee led by the Department of Energy. The NBI has contracted the Carbon Trust from the UK to provide technical support to the PSEE Team drawn from their technical expertise developed over 10 years of implementing similar programmes in the UK. “In the current context of energy security challenges and the impacts of energy price increases on company operational costs, South African companies need to manage their energy demand and meet both local and international obligations to reduce their carbon emissions,” said Yawitch. “At the same time the implementation of energy efficiency measures can improve business productivity, competitiveness and innovation as well as access to energy efficiency financial subsidies and tax incentives.” Municipal Speaker, Cllr Logie Naidoo said that the eThekwini

Municipality sees the private sector as the key partner to drive energy efficiency issues throughout the city. “Although industry is the largest consumers of energy, the private sector is also the single most influential sector in terms of energy savings potential in the city. The sector has however gone through a dramatic change with regards to energy in the past 5 years, with electricity supply constraints and increasing costs of energy driving energy efficiency interventions throughout the city.” He added that progress has already been made in some sectors to dramatically improve energy efficiency. “The Municipality has also realised the potential in implementing energy efficiency programmes. Reducing electricity in our own infrastructure also helps us demonstrate to the public that we are committed to addressing the electricity supply constraints currently facing the county,” he said. “It has allowed us to lead by example and therefore encourage our communities to take on energy efficiency and climate change as everyone’s responsibility. Similarly the private sector is able to lead by example and has the potential to galvanize the broader community into action around energy efficiency.”

Insulating oil to keep your transformer going. Well into the future.

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Enquiry no: 53

February / March 2014

POWER GENERATION

KZN Industrial & Business News

Putting the power into car batteries

esto helped upgrade production at a local manufacturer of lead-acid motor vehicle batteries, by providing a new electric drive solution for their process. The manufacturer runs a production line where vehicle and truck batteries are assembled. They were using a pneumatic solution to fill batteries with acid and evacuate the excess acid to maintain a level fill. “The customer was looking to upgrade for a number of reasons,” explains Festo Sales Engineer, Danny Waters. Their old solution consisted of multi-position DNC Cylinders. “These had to be set up mechanically for every variant change which meant lengthy changeover times between product variants. Additionally, the

customer wanted to be able to save, select and maintain all variant specific settings as an HMI function in order to reduce the margin for input errors. It was decided to move from pneumatic to electric actuators to avoid the need for mechanical set-up and any subsequent delays. The DNCE mechanical axis which was chosen as the mechanical interfaces of this drive is largely compatible with the standard cylinder DNC, while offering faster, more accurate movements offered by electric drives. Furthermore, a range of specially adapted complete solutions is available for the electric cylinder DNCE and the motors/motor units. Motion to the system is provided by the combination of the compact CMMS motor controller and servo motor EMMS. The CMMS has integrated safety functions such as protection against unexpected startup, shorter response times in the event of an error and a faster restart as the intermediate circuit remains charged. It also offers integrated EMC filters and an integrated brake chopper. Offering a choice of feedback systems, the EMMS is a dynamic brushless, permanently excited synchronous servo motor. It can be used with single-phase or three-phase motor controllers, torque optimised or speedoptimised. The modern compact programmable controller (PLC) CECC provided a smooth integration with the existing control system as the mini-controller features IO-Link, CANopen and a USB interface. Providing the interface between the system and operator, the Festo HMI, CDPX, offers advanced graphics and animations, a symbol gallery and remote access and control via an Ethernet interface. It also offers the ability to set, save and backup recipes containing variant specific settings. This modern touch technology ensures that control is extremely easy for the operator. “Through our local office we were able to supply, install and programme the machine within two weeks, while ensuring commissioning and after-sales support” says Waters. Enquiry no: 54

Contactors and thermal overload relays

he WEG range of SABS-approved CWM contactors and thermal overload relays, with a quality level proven to exceed market standards, offers a reliable solution to low voltage applications in electric panel assembly for OEMs, distributors and end users. The compact contactors include a range from 7 to 22 Amps AC-3 and a standard range from 9 to 800 Amps AC-3 presenting the most suitable contactor for any industrial application. Included in the range are auxiliary contacts and various coil voltages as well as all accessories. The WEG CWM general purpose contactor line has been designed with due consideration for industrial duty and reliability as well as extended mechanical and electrical life with dependable switching in even the most heavy-duty applications. These contactors allow total panel space optimisation, while reducing inventory is easy with CWM common accessories. All WEG contactors are tested and approved to be used under Type 1 and Type 2 short circuit coordination.

360° gas and welding solutions The Professional’s Choice Afrox offers a complete range of gases, welding solutions, safety equipment and related consumables to cover every angle of your gas and welding needs – which is why we are Africa’s leading gases and welding company. AFROX Customer Service Centre: 0860 020202

Email: customer.service@afrox.linde.com

www.afrox.com

Enquiry no: 55

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2012/12/05 11:32 AM

February / March 2014

POWER GENERATION

KZN Industrial & Business News

‘Generating’ demand in changing market

espite the prevailing tough economic conditions which many South African companies are currently encountering,

generator hire company Rand-Air reports that there is an ongoing demand for their generators as projects are still going ahead, albeit that

New partnership for alternative energy provider

lectro-Flex, one of the leading alternative energy providers in Southern Africa, has recently become the sole partner of IBC Solar products in the region. Realising the growing need for solar energy in Southern Africa, Electro-Flex saw this partnering as a natural step to being involved in Africa’s move to embrace green energy, which is seeing the continent slowly migrating from harmful fossil fuels towards environmentally-friendly and carbon neutral renewable energy. IBC Solar was founded in 1982 by Physicist Udo Möhrstedt at a time when solar technology was in its infancy. As photovoltaic pioneers, IBC Solar has had 30 years of experience and success stories, supplying customers all over the world with state-of-theart photovoltaic systems based on their common values, man-

agement and business principles. Today the German based company is active all over the globe, including Southern Africa. “We are honoured and excited to be a partnering with IBC Solar. As a global leader in photovoltaic systems, IBC Solar’s knowledge and experience can only benefit Electro-flex and its customers,” says Hendrik Roux, Managing Director of Electro-Flex. This partnership with IBC Solar is a mutually beneficial relationship; making Southern Africa greener with their combined knowledge and experience. As a sales partner of IBC Solar, Electro-Flex will profit from IBC Solar’s more than 30 years of experience, their field tested know-how and their renown in the photovoltaic industry, successfully implemented over 150,000 projects worldwide.

demand patterns have changed over the past few years in the generator and standby power sector. Rand-Air Fleet Manager Craig Swart reports that this is good news for the company, as it is testimony to the high standards of quality and technology of their products. “Customers look for these aspects in a product during challenging economic and operational times, such as those which the industry is currently experiencing,” Swart explains. “There is a definite shift in the industries where our generators are most in demand. “We are seeing more interest from companies which perform routine maintenance projects. For example, projects requiring a plant shutdown.” says Swart. When South Africa experienced its power capacity problems in 2008/9, there was significant demand for standby and emergency power as

companies from both the domestic and industrial market. During this time, and even up until fairly recently, companies which supplied generators and standby power enjoyed a ‘boom’ period while additional power stations have been under construction. However, Swart points out that the generator and standby power sector will need to adjust its strategy to mitigate for the fact that the national power supply has now largely stabilised. In addition, he adds, further key power generation installations are approaching the commissioning stage and will add significant capacity to the national grid. “Suppliers of generators and standby power will certainly need to find innovative ways of stimulating new business as the above developments take place and industry demand patterns change as a result,” comments Swart.

He adds that this is where belonging to the global Atlas Copco group is a significant strategic advantage for Rand-Air: “In a highly competitive industry, having any ‘edge’ on a competitor is vitally important and is the essence of a company’s success. Therefore, having the technological advantage is essential.” Atlas Copco has developed technology whereby a number of generators run in parallel to each other from a central location. These feed into a central software programme where their performance may be monitored at all times. This allows for necessary changes which allow the generators to run smoothly at all times and to full capacity. This adds significant value from an operational perspective, as human resource skills can then be used on other important aspects of the project. Enquiry no: 56

MicroGen A new boiler for process steam and power generation

Enquiry no: 57

Power distribution enclosures

egrand’s modular power distribution enclosures are designed for optimum efficiency and quick installation, in commercial and industrial applications. The range of XL³ cabinets and enclosures has been extended to now include XL³ 6300 enclosures which can be equipped with DMX³ air circuit breakers up to 6300 A. “These flexible XL³ 6300 distribution enclosures consist of the combination of a ‘roof-base’ assembly and structural uprights, as well as rear and side panels which can be adapted at any

time,” says Luk Ivens, general manager, Legrand Southern Africa. “Standard distribution allows the user to choose busbars and their supports, with a personal configuration for efficient power distribution The optimised distribution system offers the combination of vertical XL-part columns and horizontal XL-part distribution blocks. This system, which ensures freedom of assembly, eliminates the need to create special connections upstream and ensures time savings in installation by being able to connect appliances on pre-assembled units. An important feature of this system is the facility for quick joining to any enclosure, without the need for additional accessories. For optimum flexibility and adaptability, there are internal and external cables sleeves, as well as the capability for vertical and horizontal joining. Trunking supports, wire guide rings and cable tie bars facilitate easy wiring through these enclosures and for enhanced convenience, all side walls and top and bottom plates can be assembled after wiring. Legrand and its national distributor network also offers a technical advisory and support service. Enquiry no: 58

JOHN THOMPSON, a division of ACTOM (Pty) Ltd., provides boiler and environmental solutions and services to the power generation and industrial markets, both locally and internationally.

Cape Town: +27 (0)21 959 8400 I Johannesburg: +27 (0)11 392 0900 etienned@johnthompson.co.za

Durban: +27 (0)31 408 9700

www.johnthompson.co.za

February / March 2014

power generation

KZN Industrial & Business News

Discarded energy offers new economic possibilities

50 years of intensive coal mining in South Africa has produced around 1 billion tons of discarded thermal-grade coal fines. In the last decade, avenues of utilising this residual energy source are being explored with increasing commitment. Recognising both the economic potential and the environmental risk posed by the discards, Birkenmayer South Africa supplies mixing & granulation equipment capable of processing the fines into usable coal-based commodities. Through its provision of Eirich’s range of Industrial Mixers, Birkenmayer offers a number of ways to utilise coal waste in several market streams: briquetting/extrusion, pelletising and granulation. Each can be performed by the same Eirich mixer in different operational modes using customised binding options, as determined by the degree of transport and handling demands the product will be exposed to before it reaches

the end user. The historic discarding of coal fines is not due to its lack of thermal potential, but its intrinsically difficult handling and transport characteristics. The many heaps and slurry ponds that have emerged because of this, however, pose serious explosion and self-ignition risks during handling and are a major safety hazard. The Eirich Industrial Mixer homogenises coal fines according to an array of binding options determined by the intended downstream product application. Eirich Industrial Mixers offer excellent homogenised consistency with efficient utilisation of binding agents. • Briquetting and extrusion: Fines can be processed for briquetting and extrusion purposes. This is a high value coal market, typically aimed at European and North American export to retail markets. The relatively large size (typically 40-60 mm) and shape

of the intended end-product, as well as the degree of handling and distance to be transported, means that a high-strength and waterproof bond is essential. This application thus requires a more advanced, expensive binding. The Eirich Industrial Mixer’s output consistency allows a faster, simpler downstream briquetting and extrusion process with lower costs-per-ton. • Pelletising: Pelletising has a wide applicability in industrial demands where a cheaper heat source than is offered by conventional electrical means is sought. Intrinsically, due to both a smaller size as well as a far rounder composition than briquette pillows, these 15-50 mm coal pellets are less prone to breakage, meaning a less expensive binding option needs to be utilised. Depending on intended use, environment and transported distance, the pellets can be

1961

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Coralynne & Associates +27 (011) 422 1949

Enquiry no: 59

Leak-detection The GRID What is it?

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.

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2007

Zest acquires IMS Cape

n Manufacturing facilities on 4 continents n 55 000 motors produced per day n 3rd largest electrical manufacturer worldwide n WEG products distributed in over 185 countries n 2.5% of WEG’s annual net income spent on R&D

Middelburg branch opens

To find out more scan the code or visit: zest.co.za/sustainability

To find out more scan the code 00 ZEST (9378) | www.zest.co.za or0861 visit: zest.co.za/sustainability

2002

Port Elizabeth branch opens

BLUE IS THE NEW GREEN

2002

Rustenburg branch opens

WHY

TECHNICAL SUPPORT

1998

Trichardt branch opens Coralynne & Associates +27 (011) 422 1949

24/7

1997

Richards Bay branch opens

750 people across Africa who care Access to 26 000 people worldwide who care

1994

Cape Town branch opens

PASSION

1991

Durban branch opens

THROUGH OUR PEOPLE

1980

Zest Electric Motors established in Jhb

n We push boundaries to deliver n We listen to our customers n We focus on all our customers, big and small

WEG established in Brazil

homogenised with waterproofing characteristics. For pelletising applications, the Eirich Industrial Mixer not only provides consistent binding of the fines, but pre-granulates them, decreasing the size of downstream equipment, while increasing throughput. • Granulation: Granulated fines, of 1 - 15 mm, are best suited for electric power stations, which have the capabilities required to burn low-grade coal. Because South Africa’s power generation remains almost exclusively coal-reliant, there is an insatiable demand for this grade. The granulation of this coal is optimised solely in accordance with the nature of its transport requirements – minimised handling and smaller size means that the consistency does not need excessive strength – requiring an inexpensive binding solution. The mixer can also granulate 2 - 5 mm granules without binder, using the coal’s inherent ash content – an Eirich proprietary process. This eliminates a large cost component to the processing of the fines, but is best suited for conditions of minimal handling (in short or automated distances between mixer and power station). Granulated fines produced within the Eirich Industrial Mixer do not require additional upstream processing equipment, dramatically saving on capital costs.

in power stations

n s t ro tech is a Comtest G r o u p Company and a local manufacturer and distributor of a range of process control instrumentation and specialised systems to the South African and international markets. The company has designed and developed at the request of and, in consultation with the South African Power Utility (where 93% of all electricity is currently generated using coal) an advanced acoustic leak detection system called Inspecta FFT, to detect boiler tube leaks in coal fired utilities as well as in oxygen plants and gasifiers. This technology and equipment is now in use in power stations worldwide, where the early detection of tube leaks to reduce down time and prevent consequential damage is vital. According to the World Coal Association, the importance of coal to electricity generation worldwide is set to continue, with coal fueling 44% of global electricity in 2030. (Source IEA 2010). The Inspecta installed base includes power stations in South Africa, Germany, Australia, Turkey, India, Malaysia and China. Authorised distributors in these countries are on hand to provide all the services required to provide high levels of pre- and post-sales support as well as any spare parts required to keep the systems running efficiently. Enquiry no: 60

February / March 2014

KZN Industrial & Business News

packaging

Package deal for local industries

ohannesburg-based Kahn & Kahn forms part of the Damax Plastics & Packaging Group, and managing director David Tromp (pictured) notes that the company specialises in the manufacture and supply of industrial grade plastic products. “Our industrial plastic packaging capabilities are comprehensive, and range from bubble wrap and cable ties, to refuse bags, masking tape and seals.” For the construction industry, Kahn & Kahn specialises in plastic sheeting for foundations, walls and roofing. “To complement this flagship range, we also offer the local construction industry value-added support products such as but not limited to; damp proofing, joining tapes, refuse bags, stretch / pallet wrap, orange barrier netting, Polypropylene bags, shrink sheeting, carrier bags plain / printed, bubble wrap, tapes, plant bags, tubing, Sisalation insulation and painter’s sheets,” he explains. From humble beginnings in 1980, Kahn & Kahn today boasts a team of 40 staff members. Tromp attributes this success to the 1999 acquisition

of Kahn & Kahn by the Damax Group. “By combining its capabilities with ours under one roof, the Damax Group has enabled us to reach into new avenues of growth that were previously unattainable as a small standalone company. Kahn & Kahn has grown into a successful and well-respected business, despite a number of challenges in the local market. “As a result of economic pressures, the construction industry in particular has seen a sharp decline, which has had a direct impact on our business. This presents a major challenge, however, Kahn & Kahn has been able to weather the storm and has maintained a steady growth in profits despite these challenges.” The continued influx of cheap and inferior imports from Asia is another major challenge locally, adds Tromp. “Although these products entice end users through an initial purchase cost saving, the long term implications related to product defects and failure can prove to be immensely costly.

Kahn & Kahn prides itself on its reputation for quality, and has always risen above the trend of sacrificing quality in order to cut costs,” he continues. Tromp reveals that 2013 was a good year for Kahn & Kahn, with the company experiencing growth in profits, when compared to 2012. “The future outlook for the company is positive. Kahn & Kahn boasts a dynamic and hard working team, which has resulted in continued success year-after-year. To maintain a leading edge in the industry, one of our main priorities moving forward will be the reduction of our overall carbon footprint through the implementation of new recycling initiatives.” Looking at the local plastics and packaging industry in general, Tromp remarks that growth looks set to continue. “The plastics and packaging sector is a fast growing industry that is able to offer great value to a number of other industries. Kahn & Kahn aims to expand and be a part of this increasing growth. Our core focus for growth in 2014 is through sales,and we are introducing advanced new systems to ensure that our sales team remain leaders in their field,” he concludes.

The retail market shows the biggest demand, with 55% of flexible packaging papers used on various products for retail sale.“The increasing demand for packaged foods rides on the wave of growing development in retail infrastructure in these emerging economies, shrinking traditional markets for many products sold in loose or semipacked formats,” adds Thomson. Global plastics processing machinery demand is also expected to increase 7% annually through 2017 to $37.6 billion. The number of packaging companies exhibiting at AB7 has increased significantly over the past five years, with packaging companies from far

afield as Turkey, Australia, the United States, Ukraine, China, United Arab Emirates and Singapore showcasing their products. Last year’s show beat all expectations, attracting 268 exhibitors and 9 642 visitors. “Over 60% of visitors to AB7 are key decision-makers, managing directors, business owners, wholesalers, agents and manufacturers,” says Thomson. Craft Aid, a Mauritius-based company that packages sugar, garnered close to 30 leads last year, most of which led to concluded business deals. “Our packaging line is growing, and being at AB7 enables us to showcase these to companies from Africa and the rest of the world,” says Managing Director Gabriel Kamudu. Hein Steyn is the Sales Director for Acepak, a market leader in end-of-line packaging machinery, and had over 200 enquiries and substantial postshow sales during last year’s expo. AB7 takes place a month earlier this year and exhibitors and visitors are urged to plan accordingly. AB7 2014 will be held from 22 to 24 June at Gallagher Convention Centre, Midrand. Enquiry no: 62

Acquisition of German CSAT printing systems to boost’s company’s African footprint new market for the company. The CSAT Linoprint L rotary inkjet printing press uses the drop-on-demand inkjet method and offers a native resolution of 600 dpi and a printing speed of up to 48 meters per minute in four-colour mode. The integration of CSAT’s high-resolution digital printing systems will strengthen Markem-Imaje’s array of technologies, solutions and services, and help expand its market using their existing reputation. Linking with the highly reputable Heidelberg also creates the opportunity to develop new technology for Markem-Imaje. Enquiry no: 63

The marking and identification authority

Enquiry no: 61

Packaging companies to gain value at AB7

op local and international packaging companies will again be cashing in on the many networking and business opportunities provided by Africa’s Big Seven (AB7) to penetrate into Africa’s growing food and beverage market. Africa’s Big Seven is the continent’s biggest food and beverage exhibition and takes place at Gallagher Convention Centre, Midrand, Johannesburg, from 22 to 24 June 2014. “The booming African economy is fuelling the demand behind the phenomenal growth in Africa’s packaging industry,” says John Thomson of Exhibition Management Services, organisers of AB7. “Africa’s rapidly growing middle class consumer population is driving significant long-term growth, making it a priority market for many international packaging companies, especially in the plastics arena. Over the past six years, plastic packaging has grown by a massive 150%in Africa, with average annual growth of 8.7%,higher than in Western Europe.” The flexible packaging market in Africa is forecast to grow by an average of 5% per annum over the next four years, to 37 million tons.

ark e m - Imaj e Corporation, a global leader in product identification and traceability solutions, announced in early January the acquisition of Heidelberg’s CSAT inkjet subsidiary. CSAT, headquartered in Eggenstein, Germany, specialises in integrating digital printing and labelling systems into industrial production lines, and focuses on supplying the pharmaceutical and label conversion sectors. Rowan Beattie, MD at Pyrotec, explains “Globally, the whole industry is going the digital printing route and PackMark’s core business also forms part of the digital printing world. We use the same technology, but with different applications.” Pyrotec is the sole South African distributor of Markem-Imaje’s range of machinery and can now also offer CSAT printing solutions to its customers as a result of the acquisition. According to Beattie, the acquisition of CSAT expands Pyrotec PackMark into a wider sphere of operation and will act as a springboard to establish its footprint into Africa, an entirely

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Reach truck performs dual role

ecently Goscor Lift Truck Company (GLTC) was presented with a significant challenge by one of its clients - a packaging manufacturing concern - which it met with flying colours. The challenge was to provide a suitable machine for an application that demanded a reach truck capable of collecting large plastic bundles in roll form, weighing in excess of 1300kg, from the company’s production line then transporting them to a roll store to be stacked on a custom designed racking system up to a height of 6000mm. Stacking the rolls is a very intricate procedure, given the minimal space the operator has to work in. Precision in the movement of the forklift and its operator, as well as the accurate placement of the product, is the key to success. GLTC’s John Petrie recommended the Crown RR Reach Truck, which has a lifting capacity of 2000kg at the required lift height of 6000mm as being ideal for the task. Add to these credentials the operator directed electronic steering system, which is directed

February / March 2014

PACKAGING

by means of a multi-task control handle and which gives the operator the option to sit or stand whilst driving. This, together with a set of locally designed and custombuilt rotating forks, which are manually adjustable, allows for precise handling. The Reach Truck is able to upload the large plastic rolls with its forks adjusted at a 45° angle. This allows the reach truck to scoop the product up to sit firmly at the base of the angled forks, just in front of the carriage, for safe handling. The plastic rolls are manufactured in different sizes, so the ability to adjust the angled forks “inwards” or “outwards” according the products width, is crucial. Once the plastic rolls have been transported safely to the roll store, a cylindrical-shaped metal sleeve is placed through the centre of the roll. The rotating forks are then adjusted to the standard position and locked in place. 150mm from the front tip of these forks, a recess allows the metal sleeve carrying the large roll to fit securely before the load is lifted. When unloading, the product is lifted to the required height and placed in the exact stacking position by means of a double-deep reach action. The forks can then be rotated from the 90° position to 0° position (normal fork type) to handle standard pallets. The rotation is manual and can be done in seconds. “GLTC has provided a solution that enables the client to use a product that essentially performs a dual role - i.e. of a reach truck as well as a counter balance truck in challenging circumstances,” concluded Petrie. Enquiry no: 64

KZN Industrial & Business News

A MAP for Success

hile MAP (Modified Atmospheric Packaging) is not new, it is becoming more widespread as manufacturers and retailers in the food and beverage industry are becoming increasingly aware of the benefits it brings, not only to their businesses but also to their customers. “The demand for MAP products is on the increase. The more food manufacturers experience the benefits of MAP, the more awareness is created, and the more it becomes an important part of their supply chain,” says Arthi Govender (pictured), Specialty Gas Sales Manager at Air Products. “The benefits of MAP extend from producer and manufacturer, to retailer and ultimately to the consumer,” Govender continues. “By extending the shelf life of a food product, MAP translates into convenience, and a more appealing, fresher product. For the retailer, MAP means less spoilage, lower inventory and better distribution efficiencies.” MAP technology uses three main gases to enhance the shelf life of a product: oxygen, carbon dioxide and nitrogen. Used in various carefully controlled combinations, or mixtures, according to the application or product, the levels of these gases in the atmosphere surrounding the food product are altered in order to enhance the appearance and freshness of the product. “In simple terms, the composition of the atmosphere (air) surrounding food is modified according to the type of food, in order to

extend its shelf life,” Govender says, dispelling any misconception that MAP is in any way controversial or risky. She likens the process to using an oxygen mask to assist breathing. “MAP does not affect the product in any way other than modifying the surrounding air. There is no artificial enhancement – it is entirely natural. However, it also means that it will not improve an already inferior product – in other words, it does not make a product that might be bad for consumption, good for consumption.” The science of shelf life extension and improving presentation is based on extensive laboratory research, and is subject to the most stringent health and safety standards. In this way, Air Products is able to offer a value-added service to its clients and customers. “Our team of product specialists includes a qualified Food Technologist with vast experience in the food industry. We are therefore able to advise the customer on GMP (Good Manufacturing Practice) and hygiene issues, as well as assist with customer trials. With the use of technology, such as an oxybaby (a handheld device which analyses modified atmospheres in packages) we are able to verify the gas results in each package,” says Govender. “Quality and consistency of product take precedence in our offering, and a key part of the value chain is to be able to assure our customers of the most stringent safety standards,” notes Josua le Roux, General Manager: Central Support at Air Products Enquiry no: 65 South Africa.

Continuous Inkjet Printer

he ICON S-100 CIJ printer is an economical and easy-to-programme ink jet printer with a stainless steel, robust waterproof design. An IP55 enclosure and low maintenance print-head ensures reliability in the most demanding and continuous of inkjet printing environments. Its 10” touch screen display allows users to easily change settings, print parameters and create messages, using its proprietary ICONbased software. The ICONS-100 CIJ printer is capable of the high-speed print applications demanded in industries such as; food and beverage, pharmaceutical, cosmetic, automotive, timber, etc. This CIJ printer can print at speeds

92_FuturePac_fcp.indd 1

of up to 6m per second and uses 5 – 32 dots to provide a high quality print. Kyle Parker, MD of Traceability Solutions says, “The ICON S-100 CIJ printer is extremely economical as it has no expensive ink modules to replace and no ink tanks to change between services.” The Icon S-100 printer provides optimum adhesion with its fast-drying printing ink and a low-maintenance print head. The printer also carries a full range of inks including white and yellow and offers up to 4 lines of print for text, logos, barcodes and 2D data matrix codes. Enquiry no: 66

8/30/10 12:50:50 PM

February / March 2014

KZN Industrial & Business News

CONSULTING ENGINEERS

Sustaining consulting engineering is key to growing the economy

onsulting Engineers South Africa’s (CESA) newly appointed President, Abe Thela, recently presented his presidential message. With the theme of ‘Sustaining Consulting Engineering is Key to Growing the Economy’ Thela stated that the National Development Plan (NDP) was created in order to develop the South Africa’s economy. Government through the NDP has identified infrastructure development as key to the socio economic development of the country. Thela believes that the NDP and its objectives will never come to fruition unless there is involvement of consulting engineers at the forefront of this development. Consulting Engineering, although a relatively small sector, has a large multiplier effect on the development of infrastructure as they are the designers that create the large scale infrastructure projects that employ large numbers of people during the construction, operation and maintenance phases of infrastructure. CESA is pleased that Government has prioritized infrastructure development as a key component of accelerated economic development. In his 2013 medium term budget policy statement Minister Pravin Gordhan allocated R827billion to infrastructure for the three year period ending 2015/16. They welcome this announcement but are concerned government has not yet revealed the project pipeline going forward. The industry needs this information to commit to long term planning and investment in more resources. Although there had been delays in implementation , the organisation is looking forward to an acceleration of this programme in 2014. With Government’s plan to grow the economy and triple GDP by 2030 the Consulting Engineering Industry has a significant role to play in achieving this growth through infra-

structure develside price and opment. Thela BBBEE points. stated, “The At the same time Consulting they challenge Engineering Government industry is facto conduct a ing a number of comprehensive challenges but research and by far the most review of the curchallenging is rent procurement how consulting system to deterengineering sermine its impact vices are curon the consultrently procured, ing engineeras it is stifling the ing industry and industry”: infrastructure Lefadi Makibinyane, CEO (left) and Abe Thela, newly While CESA development in elected President, both of Consulting Engineers South does not the country. Africa oppose comKPMG estipetitive bidding, mated an infrawhich is a constitutional imperative, they do not structure spending gap of R6.5 million between believe that price should be the determining the planned MTEF and PICC infrastructure basis. The organisation believes that it should spending and the infrastructure spending be based on quality taking into account the bidder’s qualifications, experience, capability and innovation. The bulk of infrastructure cost lies in coniviero celebrated the start of 2014 with struction and maintenance with the cost of an R800 million improvement to its order consulting engineering only being 1 - 2% of book. The group’s new contracts are spread the project lifecycle cost. So it makes perfect between the provinces of Gauteng, KwaZulusense that a procurement system that takes Natal and the Free State, reports CEO Neil the entire project life cycle into account should Cloete, and they include building and civil be implemented when procuring consulting engineering projects. engineering services. Liviero’s new undertakings are for clients Consulting engineers need to go back to that include SANRAL, Growthpoint Properties their very important role of being trusted advisand Mangosuthu University of Technology . ers to the client providing advice on planning The contractor is building a new multiand design and its impact on construction storey private hospital in Durban that is operating and maintenance costs. scheduled for completion in the latter part of As an interim measure CESA calls on 2015. Also in KwaZulu-Natal, new student Government to reintroduce quality as part of accommodation is being built by Liviero at the total procurement points calculation alongthe Mangosutho University of Technology

based on the NDP target of 10% of GDP. Part of this spending gap will have to be funded by the private sector. The NDP also intends to raise the private sector infrastructure contribution from 10% to 20% of GDP to drive the intended growth. CESA states that a clearer project pipeline, more standardisation of deal structures, policy stability and better information about the performance of projects at their various stages would all encourage infrastructure debt investment. SA business has further identified regulatory uncertainty, inclusive growth, education and skills and labour relations as affecting investor confidence. CESA is committed to working with Government to address these constraints where they affect the consulting engineering sector. The potential of PPPs to entice private sector investors into infrastructure development is not fully appreciated in SA. Enquiry no: 67

Local company’s R800 million boost in Umlazi, and alterations and extensions are being undertaken at an industrial park in Pinetown. In southern Gauteng, the company is undertaking a R300-million upgrade to a regional shopping centre. On the civils side, Cloete explains that Liviero’s new contract for SANRAL in the Free State entails the construction of a new interchange at Botshabelo, on the N8 motorway. “These awards are a welcome boost to our order book and provide a solid platform from which we can continue to expand operations in a focused and controlled manner,” he concludes.

Dramatic rise in use of light steel frame building

An industry survey by the Southern African Light Steel Frame Building Association (SASFA) has revealed a dramatic increase in the use of the light steel frame building (LSFB) method in South Africa. SASFA director John Barnard says that the survey showed that the mass of steel used in South Africa to profile LSF sections increased by 6% during 2013, compared with the previous year. However, exports declined by 30% largely due to the establishment of manufacturing capacities in neighbouring countries, while the local market for LSFB grew by 21%, considerably more than the 7% growth recorded for the building industry in South Africa. “As the volume of steel used purely for light steel roof structures remained fairly constant, all the growth came from steel used for complete LSF buildings, almost doubling the previous year’s figure for this sector”. Barnard says. According to Stats SA, the floor area of all buildings completed in South Africa during 2012 / 13, including additions and alterations, is reported to be 10 million m² - a growth of 7% on the previous year. New residential buildings (including alterations) made up 68% of the area of all buildings completed, and showed a 3% growth. A significant 24% of all buildings (residential and non-residential) completed, comprised of “Additions and Alterations”. Industrial buildings and warehousing formed the major sector in the non-residential market, with 40% of the floor area, followed by office buildings (32%). The latter sector

showed massive growth during the past year, more than doubling the floor area completed during the previous year. “Based on building plans approved, we can look forward to a 16% growth in building activity during the next 12 to 18 months, keeping in mind that there is a lag of some 9 months between plans approved and buildings completed,” says Barnard. In the 2013 survey, as in the past, SASFA approached the South African manufacturers of light steel framing to determine the volume of thin gauge high strength galvanized steel sheet they had processed during the past year . The manufacturers reported throughput of 24 200, reflecting 6% growth. “Supply into the local market increased by an astounding 21%, while exports from South Africa into Sub-Saharan Africa declined by 30%. This decline can be ascribed to profiling capacity that is being installed in the neighboring countries, as well as the increase in local demand,” Barnard says During 2013, LSF roof trusses used with masonry or in industrial buildings constituted 54% of locally sold LSF. Roof structures covering a total floor area of 1.31 million m² was produced, on par with that during the previous year. “Based on Statssa figures for buildings completed in 2012/13 (excluding low cost housing), light steel roof trusses captured 13% market share during the period”, Barnard says. Complete buildings - wall panels with roof structures - covering a total area in excess of 500 000 m² were built in LSF in South Africa during 2012/13, which is an 80% increase on the 2012 performance. LSFB is increasingly being used for external (and internal) walling of multi-storey office and commercial buildings while a growing volume of additions to existing buildings is also reported. In addition, a number of project enquiries from neighbouring countries have been received. “The encouraging fact that the government recently announced that innovative building technologies, such as LSFB, will increasingly be preferred for new schools, clinics and student accommodation, will add additional growth potential,” says Barnard. Enquiry no: 69

Enquiry no: 68

The world needs fewer engineering companies. Rebranded as Royal HaskoningDHV, SSI Engineers & Environmental Consultants believes in being more than an engineering company. Our rebranding to Royal HaskoningDHV ushers in a new class of engineers and consultants, offering solutions for the sustainable interaction between people and their environment, ultimately enhancing society together.

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CONSULTING ENGINEERS

February / March 2014

KZN Industrial & Business News

Cementation training simulation training gets ‘real’

he Murray & Roberts Cementation Training Academy near Carletonville has taken the use of simulation combined with the use of other supporting technology to the next level. Underpinned by a battery of learner support programmes, learner trackless mining machine operators are able to progress from a novice status through a series of carefully designed stages that culminate towards operator applied competence. “We recognise that simulation has significant potential beyond what it is typically used for and we intend to fully exploit this potential,” Tony Pretorius, risk manager at the Murray & Roberts Cementation Training Academy, says. “Beyond purely training, we make use of simulation for pre-employment screening, learner diagnostic assessment, accident/incident reconciliation, enhancement of psychomotor skills, operator proficiency charting and engineering design.

“As part of our long term strategy, we intend to include simulation to support mine design and to use it to role-play incidents and accidents that have occurred in the past in the

workplace to ensure that we continue mining by lessons learned.” The Training Academy is also poised to entertain more projects focussed around trackless mining, recognising that simulation is a powerful tool to accelerate the competency journey of an operator. It accurately tests learner proficiencies across three areas namely; health & safety, productivity enhancement and machine appreciation. The associated examples test reflexive competencies through the simulation of common workplace and work related hazards and risks in a virtual environment at a fraction of conventional training related costs. Learner training at the Murray & Roberts Cementation Training Academy begins with a PC-based e-learning programme developed from OEM information relating to specific machinery and actual video footage of this machinery in action.

This combination of literature, diagrams and video imagery lays down the first level of foundational competence — knowledge and understanding. The learner then proceeds to the next level that comprises a series of visual-based training modules. It is here that the learner is taught that every action has a consequence. The objective is to impart consequential thinking, which ensures that once in the field, the candidate will take the correct course of action to prevent a negative reaction. For example, the health and safety modules focus on issues such as pedestrians, fire, and brake failure by testing the learner’s reactions in a “what if” scenario. Thereafter the learner is introduced to the virtual environment by engaging in video-type games relating to the theme of machinery operation. These games, highlighting tasks such as load hauling, drilling and dumping, expose the learner to the concept of what his/her future job will entail. The next stage is the “pre-simulation” environment, where the learner observes the experiences of other operators on the simulator. “The objective here is to psychologically desensitise the learner in order to remove any fear of operating the simulation equipment,” Pretorius explains. “Ultimately this process minimises time wasting on the simulator, because by the time the learner gets to this point, he/she has a very good idea of Enquiry no: 70 what to expect.

Poor project results – are soft skills the solution?

he recent spotlight on the Infrastructure Development Bill highlights the problems our country faces with getting projects completed within budget and on time. This is not an issue exclusive to the public sector or South Africa. Projects are not only an integral part of infrastructure development, but also a key element in service delivery improvement, technological advancements and environmental sustainability imperatives. Problems with project completion reduce resources available for developments and improvements in other areas. A staggering 42% of respondents to a recent survey said they did not know how often projects are completed on time, on budget and within scope. Well-known challenges related to project management experienced by even seasoned project managers include lack of support resources and the variety of complex project management tasks that need to be performed. Lesser-known, and less technical, inhibitors to successful project completion include the lack of knowledge about project completion, as well as a lack of opportunities for the formal recognition of successfully completed projects. When project participants across the supply chain are not aware of the project outcome, motivation for future projects is reduced, posing a significant risk for project funders. The lack of feedback may also result in the continuation of project-related practices that are no longer needed, leading to wasted resources. “The communication of project outcomes does not receive nearly enough focus,” says Keabetswe ‘KEA’ Mpane (pictured), SAPICS director. “It is in the best interest of an organisation to promote the use of a supply chain management mindset that spans the dynamic relationships of project participants located inside and outside organisations.” According to APICS, the US-based professional association for supply chain and operations management, supply chain project management “enhances the best of a supply chain professional’s skill, including forecasting, soft skills, planning, and risk management. This combination builds strategic and advanced management experience and positions the professional for a higher management position.” Enquiry no: 71

February / March 2014

KZN Industrial & Business News

INSTRUMENTATION, MEASUREMENT & PROCESS CONTROL tions of parameters and other codes. The HIM also has multiple language options to address global needs. Unique to the PowerFlex 520-Series AC drives, AppView and CustomView tools help speed up configuration by providing groups of parameters for common applications and by allowing users to save their settings to new parameter groups. These tools can be eas-

ily accessible via the HIM, as well as configuration software tools. Connected Components Workbench software from the company also helps speed up drive configuration and further reduces development time with online and offline configuration, AppView and CustomView groups, and startup wizards. Machine builders gain more time to focus on design and improve a machine’s competitiveness. For more sophisticated networked machines, builders can take advantage of an optional dual-port EtherNet/

Sensor measures time of flight

eliable background suppression, colourindependent detection and easy switch point setting are the outstanding features of the photoelectric PMDLine sensor OID200 from ifm electronic. It even detects shiny surfaces like stainless steel without any difficulty. This sensor with PMD technology (photonic mixer device) combines the advantages of long ranges, reliable background suppression, visible red light and high excess gain in one unit. In the same price range as conventional sensors, the OID200 offers a clever alternative. Another benefit of the ifm sensor is that the switch point can be set with a simple turn of the setting ring. A scale shows the distance set. This allows the switch point to be set before installation. Whether shiny, matt, dark or light objects of any colour, the OID200 sensor ensures reliable background suppression. Even with acute angles of incidence of the laser beam, the object is accurately detected. This provides Enquiry no: 73 high flexibility of installation.

the top and bottom when installing into a cabinet and can be installed vertically or horizontally, as well as side by side in either orientation. This smaller clearance and mounting flexibility can help customers reduce the panel space. In

IP adapter for the PowerFlex 523 AC drive. This module supports ring topologies and provides device level ring (DLR) functionality, which can help provide network resiliency and drive machine availability. When a DLR network detects a break in the ring, it quickly provides alternate routing of the data to help recover. The dual-port adapter supports linear topologies in addition to ring configurations. Ring topologies can remove the need for an external switch and reduce unnecessary cabling. Adding a dual-port EtherNet/IP adapter to a PowerFlex 523 AC drive provides automatic device configuration, which saves time by automatically downloading configuration files when a drive is replaced. The drive has a power range of 0.25 hp (0.2 kW) to 15 hp (11 kW) and motorcontrol options, including volts per hertz, sensor-less vector control and Economizer mode in sensor-less vector control. The modular design of the PowerFlex 523 AC drive gives machine builders greater installation flexibility. Removing the drive’s control module from its power module further reduces start-up time, as machine builders can complete configuration and installation simultaneously. The PowerFlex 523 AC drive requires 50 mm (2”) of clearance on

addition to the flexible installation, the PowerFlex 523 AC drive is rated up to 50 °C (140 °F). With an optional control module fan kit, the drive can withstand temperatures up to 70° C (158 °F) with Enquiry no: 72 current de-rating.

New Process Measurement Solution

Head Office: 012 661 0830 KZN Sales: 082 773 6737 WC Sales: 082 784 0088

www.loadtech.co.za

New generation tools… Next generation performance! This trio of new Fluke infrared cameras is equipped with LaserSharp™ Auto Focus guaranteeing consistently focused images. Every. Single. Time.

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Infrared camera users know that focus is the single most important factor to consider when conducting an infrared inspection. Without an in-focus image, temperature measurements aren’t accurate and it’s much easier to miss a problem. LaserSharp™ auto focus tells you exactly where you are focusing. It uses a laser to calculate the distance to your target BEFORE it focuses. Just fix the red dot on the equipment, pull and release the trigger and you have a perfectly in-focus image. Simple!

The PMX measuring amplifier system Measurement, testing, automation

PMX has been specifically developed for use in industrial production and test benches. Powerful, precise, reliable and highly efficient. n■

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PMX is cutting-edge technology from HBM. More information: www.hbm.com/pmx

HBM Test and Measurement

Elton Murison

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phone +27 (12) 809 9500

Ti300

Ti200

Comtest Distribution 10 Enterprise Close Linbro Park 2090 Tel: 011 608 8520 info@comtest.co.za www.comtest.co.za

VSquared Marketing V2/11957/October2013

nspired by global drive-user input, Rockwell Automation engineers designed the Allen-Bradley PowerFlex 520-Series of compact AC drives, including the new, economical PowerFlex 523 AC. Ideal for builders of simple, stand-alone machines, the PowerFlex 523 AC drive balances user needs for “just enough” control with a design that lowers the total cost to design, develop and deliver machines. “When we designed the PowerFlex 520-Series drives, we spoke to hundreds of drive users around the world to learn first-hand which features they value most today and would want five years from now,” says Adrian Van Wyk, Business Manager, Power and Components (Southern & Sub-Saharan Africa), Rockwell Automation. “Stand-alone machine builders wanted ‘just enough’ motor control and emphatically shared the need for features that ease configuration and speed installation. This is why we designed the PowerFlex 523 drive.” To make configuration easier, machine builders can use a standard USB connection for uploading and downloading drive-configuration files. They also can programme the drive through its built-in human interface module (HIM), which displays data on the drive’s LCD with scrolling QuickView text and detailed explana-

“Just Enough” control

instrumentation, measurement & process control

Most sustainable corporations index

ohn s on Controls, a global multi-industrial company with established core businesses in the automotive, building, and energy storage industries, has announced that Corporate Knights has again put the company on its 2014 Global 100 Most Sustainable Corporations Index. The Global 100 is an annual project and inclusion on the list is limited to a select group of the top 100 large-cap companies in the world. The Global 100 is recognised as the gold standard in corporate sustainability analysis and ranking. Companies named to the Global 100 are the top overall sustainability performers in their respective industrial sectors.

“Our selection is due to the hard work of our 170,000 employees around the globe who recognise the importance of sustainability in their work,” said Alex Molinaroli, chairman and chief executive officer of Johnson Controls. “Sustainability is at the heart of what we do for our customers and the communities we serve.” Johnson Controls has been named to this elite list four times since inception in 2005. “We are pleased to see the inclusion of Johnson Controls on the 2014 Global 100 Index. Corporate Knights congratulates Johnson Controls on being the top ranked U.S.-

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.

The Power of Knowledge Engineering SKF South Africa (Pty) Limited Tel: +27 11 821 3500, Fax: +27 11 821 3501, Email: sales.za@skf.com, Web: www.skf.co.za

based automobile and components company on the list in 2014,” said Toby Heaps, chief executive officers of Corporate Knights Inc. Added Neil Cameron, (pictured) GM of Johnson Controls Building Efficiency in Africa, “This achievement is testimony of our commitment to sustainability and the environment. Sustainability is ingrained in our DNA and we strive to achieve this across our company and to our customers – world-wide, we focus on our own environmental performance with the same discipline that we apply with our customers and continue to review our operations and supply chain to identify continuous improvement opportunities to make products in more earth-friendly ways.” Enquiry no: 74

New thermal imagers

luke, represented locally by the Comtest Group, has introduced two new thermal imagers, the Ti105 and TiR105 - the latest addition to Fluke’s series of lightweight, rugged, and easy to use imagers - specifically designed for use by maintenance professionals. The Ti105 and TiR105 offer the popular Fluke IR-Fusion technology feature, not normally found in thermal imagers in this price class. The Ti105 and TiR105 find application in industrial plants; commercial buildings and facilities; government buildings; schools; hospitals; electrical, water and natural gas utilities, and residential dwellings. The Ti105, specifically, helps plant technicians, HVAC/R professionals, and electricians maintain and inspect electrical and mechanical equipment and components, enabling them to save time and money by finding potential problems before they become costly failures. The Ti105 allows technicians to troubleshoot in seconds, lessens the likelihood of unplanned

SKF South Africa - Celebrating 100 Years of Innovative Solutions

February / March 2014

KZN Industrial & Business News

downtime, and allows regular inspections from a safe distance. The TiR105 is uniquely designed for building inspection and energy audit professionals to evaluate and report insulation problems, air leakage, moisture issues, or construction defects delivering a huge competitive advantage by helping them work faster and more efficiently. It quickly documents visible proof of problems so that repairs can be made and then verifies that the repairs have been done correctly. They are light, rugged, and the easiest-to-use of Fluke’s range of professional thermal imagers, with features such as: • IR-OptiFlex focus system, which allows the user to discover issues significantly faster whilst giving optimum focus. Manual focus is also available, on the same machine, for optimal flexibility. • IR-Fusion technology - the industry’s only point-and-shoot IR-Fusion camera. Fluke patented technology blends digital and infrared images into a single image to precisely document problem areas. • Multi-mode video recording – Troubleshooting is made simple with the industry’s only thermal imager that records focus-free video in visible light and infrared with full IR-Fusion capabilities. It monitors processes over time, and creates infrared video reports, troubleshooting frame-by-frame. Downloadable to PC for video viewing and analysis. • IR-PhotoNotes annotation system - exact references to problem areas can be noted by capturing up to three digital photos per file. Images of equipment, motor nameplates, workroom doors or any other useful or critical information could be added. • Superior Image Quality and IR performance • 160X120 FPA uncooled Microbolometers • 3.5” colour LCD with clear protective cover and adjustable brightness for easy viewing most conditions • Excellent thermal sensitivity (NETD) to see even the smallest temperature differences The Ti/TiR105’s advanced features include the Fluke-patented IR-Fusion (picture in picture) technology, which overlays a PIP infrared image over a full-spectrum image allowing users to identify and document problem Enquiry no: 75 areas.

Do you have an Enquiry? All articles end with an enquiry service number. Readers are encouraged to complete the form on page 47 should further information and contact details be required.

February / March 2014

KZN Industrial & Business News

instrumentation, measurement & process control

SA’s first accumulator testing solution

ectra Automation, a member of the Hytec Group of Companies, was recently approached by Hytec Fluid Technology (HFT), a fellow Group member, to design and build South Africa’s first solution for the pressure testing of hydraulic accumulators that is necessary for the recertification processes which is required by law. Tectra Automation provided a system that could test up to three accumulators at a time and that would measure, record and provide a report of the test results.

As HFT stock and supply a large variety of sizes and capacities of accumulators, the test bench had to be adjustable to be able to accommodate from the smallest 1 litre to the largest 150 litre accumulators. “In essence the testing process involves pressurising the units to a certain test pressure and then checking for leaks. Once the pressure is released the accumulators are then checked for permanent deformation using a mechanical go/no go gauge,” says Kevin Lombard, General Manager of Tectra Automation. “In our opinion, this presented a problem as you have to rely on the operator to confirm that the gauge is in fact used correctly. It also presented a problem in that it required several different sizes of gauges to be manufactured as HFT test many different sizes of accumulators.” Tectra Automation therefore decided to manufacture the test rig using its Bosch Rexroth aluminium profile range. The design entailed using three vertical beams with adjustable holding plates to accommodate the various lengths of accumulators. Instead of having the expansion checked manually, Tectra Automation developed an electronic measuring system using two Bosch Rexroth guide rails mounted back to back. The one unit allows the re-positioning of the fixed measuring face to accommodate different diameters whilst the second unit consisted of the Bosch Rexroth integrated Measuring System (IMS) with a measuring resolution of 1 micron. “As the whole test is conducted under very high pressures the test system has to accommodate for the highest levels of operator safety possible. “This we achieved by placing the test system behind a safety guard made from Bosch Rexroth Ecosafe fencing with 6 mm polycar-

bonate sheeting in place of the woven wire mesh. The safety is further enhanced with an interlock on the cell door that prevents the operator from testing the system whilst the door is open. “The calibration of the system was performed by a local authority and the person performing the calibration was astounded by the level of accuracy achieved for such an application,” adds Lombard. Besides the mechanical structure Tectra Automation was also responsible for the design and integration of the data capturing and certification system. A Bosch Rexroth L20 PLC was used to control the complete test procedure as well as to perform the data capturing from the measuring system and to control the pressure in the Maximator pressure intensifier.

The captured data is transferred to a desktop PC which houses the visualisation and reporting software. All software was developed in house by Tectra Automation whilst the information is stored in an MS Excel database allowing ease of reporting and storage. The ease of integration between the Bosch Rexroth measuring system and the PLC enabled the company to produce a robust industrial type measuring unit capable of very high accuracy in a fraction of the time it would normally take to develop such equipment. “HFT were extremely satisfied with the outcome of the test unit as it is not only the first of its kind in South Africa, but it in fact surpasses the test units used by overseas manufacturers of the accumulators” concludes Lombard.

Keeping

our focus

on you!

supplier

• 40 years’ experience in specialist sensing technology

• Application appropriate sensing,

Enquiry no: 77

SPECIALISTS IN INDUSTRIAL AUTOMATION MOTION & CONTROL PROCESS & CONTROL TURN-KEY SOLUTIONS (PLC & SCADA) PRODUCTS FOR THE MINING INDUSTRY

SUPPLIERS OF Southern Africa

WWWA.division PNEUMAX .CO.ZA of the Set Point Group KwaZulu Natal

T: +27(0)31 700 9483 • F: +27(0)31 700 9487

control and motion detection solutions

• Local applications knowledge coupled with state-of-the-art

counting, sensing and motion

and heating pipes. It accurately locates cables by displaying a specified letter on the receiver. The AT-2032E is shipped in a set consisting of transmitter and receiver in a robust, shock-proof case. The transmitter signal is indicated optically and acoustically. A clear, easy-to-follow instruction manual with application examples is included as well as additional transmitters for extension purposes or to distinguish between multiple sig-

nals. The AT-2032E has a LED bar display for intensity and 7-segment display on receiver for number or letter indicating the transmitter code. It is rated CATll/250V and has Safety Certificates EN 61010-1/EC 61010. The power supply comprises a 1 x 9V battery, lEC 6LR61 (receiver); 2 x 9V battery, lEC 6LR61 (transmitter) and it weighs approx. 1.8 kg.

COMPONENTS FOR PNEUMATIC AUTOMATION DUST FILTER COMPONENTS ACTUATORS & AUTOMATED VALVES PROCESS SOLENOID VALVES TRAINING & TRAINING EQUIPMENT FITTINGS & TUBING DECELERATION & VIBRATION TECHNOLOGY VACUUM TECHNOLOGY

• Leading southern African

specialist sensing technology

Hands-on cable locator

Amprobe’s AT-2032E cable locator covers all application areas (live or de-energised), obviating the need for additional devices. The AT-2032E locates cables in walls; interruptions and short circuits in cables; fuses and assignments to circuits; accidentally concealed sockets and distribution boxes; interruptions and short circuits in unshielded under-floor heating as well as the tracing of metallic water

Enquiry no: 76

detection technology

• Products conform to the highest international quality standards

• Support with a well-equipped

electro-mechanical/electronic workshop

• Representatives in Cape Town, Durban, East London, Port Elizabeth, Namibia and Zimbabwe

• 24/7 technical hotline

Products include:

• Counters and encoders

• Photoelectronic sensors

• Opto-electronic switching devices

• Flow and level sensors • Speed measuring and monitoring equipment

• Safety light curtains

your sensor solution Tel: 011 615 7556 • Fax: 011 615 7513 e-mail: clive@countapulse.co.za

February / March 2014

instrumentation, measurement & process control

Reliable class 2 surge arrester he SLP-275 V from Saltek is a reliable T single pole Class 2 varistor-based surge arrester to protect against induced surge

currents in installations in LV distributions at the boundary of LPZ 1 and LPZ 2 zones. The module guards against overvoltage effects induced during a lightning strike and switching overvoltages. Operating on a 230 V AC nominal voltage, the module has a 40 kA (8/20µs) maximum discharge current, a 25 ns response time and operates in a -40 to +80°C temperature range. The SLP-275 V features a replaceable varistor module and has visual fault signalling. It meets EN61643-11 +A11 standards and IP20 protection requirements. Enquiry no: 78 Saltek is represented locally by Surgetek.

Our Software: Adroit 8 SCADA Adroit Report Suite Adroit Alarm Management Adroit SCADA Intelligence MAPS

KZN Industrial & Business News

Prestigious business award T he Comtest Group - distributor of Fluke, the leading OEM of electrical test equipment worldwide, has been awarded the prestigious 2013 African Electric Test Equipment Customer Service Leadership Award by Frost & Sullivan, global research analysts. For the past 50 years, Frost & Sullivan has been involved in global research enabling it to monitor more than 250 000 companies worldwide, operating in over 300 industries. Key bench-marking criteria for the Customer Service Leadership Awards included quality and timeliness of service, the impact of service on customer value, as well as the cost of service to their customers. To support its evaluation of best

practices across multiple business performance categories, Frost & Sullivan employs a customized Decision Support Matrix (DSM) - an analytical tool that compares companies’ performance relative to each other with an integration of quantitative and qualitative metrics - allowing their research and consulting teams to objectively analyze each company›s performance on each criterion relative to its top competitors and assign performance ratings on that basis. A spokesperson for Frost & Sullivan says, “Independent analysis of the Test Equipment market clearly shows that Comtest’s customer service has made it possible for Fluke, the global leader in electrical test equipment worldwide, to stand out as the lead-

er in many electrical test equipment product segments in Africa. “As a reliable source of information on technologies and applications related to electrical test equipment, Comtest helps African customers make the choice of accuracy and safety for their businesses, thus avoiding potentially costly mistakes.” “The company has also developed a large distribution network for electrical test equipment across Africa, making such instrumentation easily accessible to Africans across the continent. All of these efforts make Comtest the worthy recipient of the 2013 Frost & Sullivan Customer Service Leadership Award in the Electrical Test Equipment Market.” Enquiry no: 79

Switching and measuring ultrasonic sensors

operating ranges and Lonlyonger broader areas of application are two of the features offered by

Leuze’s two new ultrasonic sensors. Suitable for switching and measuring applications, the new devices effectively expand the Leuze line of ultrasonic sensors. The Leuze HTU 418B and Leuze DMU 418B have an operating range of up to 1 300 mm, while the Leuze DMU 430B measuring devices have an operating range of up to 3 000 mm. These fully metal-enclosed ultrasonic sensors offer protection to Class IP 67. The series are available in cylindrical M18 as well as M30 metal housings, with much shorter design compared to the predecessor models. This means the sensors are easy to install in locations with limited space using

the lock nuts on the external threads. Both series are equipped with an improved teach function: two push buttons for defining two independent switching points simplify setup and increase flexibility when using the sensors. Device types with an IO-Link interface ensure the intelligent, simple and user-friendly connection and activation of the sensors. Temperature compensation prevents measurement errors that could

be caused by various environmental conditions. Four operating modes, e.g. for changing from synchronous to multiplex operation, offer high flexibility during use. The ultrasonic sensors operate using a switching behaviour that is largely independent of the surface of the sound-reflecting materials. They are available with various sound lobes, i.e., with different opening angles. The narrow sound lobes in particular permit the detection of the smallest of objects or the detection through the smallest of apertures at short response times. Countapulse Controls is the official distributor for Leuze sensors in southern Africa and is able to offer technical support including assistance in selection of the most appropriate sensors for any given application. Enquiry no: 80

Control your robot

ontinued automation of processes within the manufacturing industry in southern Africa is fuelling demand for worldclass robotics that will enable local companies to compete on a global stage. Advanced control equipment that ensures the smooth operation of robotics out in the fields is also being used to manipulate the

robotics to work ever faster and more accurately. Like the central nervous system of a living creature, signals are constantly transmitted between these controllers and robotic devices in order to facilitate effective operation of the processes. In most manufacturing environments however, conditions are arduous, with extreme tempera-

tures, excessive mechanical forces and sometimes chemicals and contaminants that can interfere with machines. As a result, careful attention needs to be paid to designing and manufacturing control cablings paths that can withstand the rigours while performing flawlessly over the duration of the manufacturing process. Robotic cabling, harnessing and accessory specialists Helukabel, are at the forefront of technology to interface controllers with robots. The company’s expertise ensures that the “central nervous system” of an operation continues to work flawlessly, as it was designed to, for years to come no matter what conditions need to be contended with on site. The company’s Robotec Systems Gmbh subsidiary works with customers around the world who require robotic automation in their operations. Robotec engineers are able to develop pre-assembled cable protection systems (Dress Packs) for robots and handling systems, as well as offer additional services to ensure the optimal performance of robotic systems for almost any application. The services they offer include system analysis, consulting, planning, installation, service and warranty of mass-produced cable protection systems for robots in automation systems. Control pathways are tailor-made to suit customer’s applications with products that include dress package systems and associated systems for automation, handling, and spot welding, as well as gas-shielded weldEnquiry no: 81 ing and laser welding.

February / March 2014

KZN Industrial & Business News

instrumentation, measurement & process control

Local company catapulted into the e-house market A

s Zest WEG Group company, Shaw Controls, prepares to despatch the last two units of an order placed by a large materials handling company for seven electrical houses (E-Houses), the company is positioning itself to elevate the design, manufacture and supply of this technology to one of its leading offerings. The seven E-Houses will be installed onto stacker and reclaimer machines being deployed at a coal mine and sea port in Mozambique. “This is the largest single order in our company’s history to date and our first E-House order as a company within the Zest WEG Group.

Much of the design information was leveraged off our holding group company in Brazil where numerous E-House projects have been successfully completed by WEG. This order was secured against both local and international competition,” Shaw Controls managing director Bevan Richards, says. The contract was concluded on the basis that our Group was able to provide a complete solution. “We have a clear vision for future growth and expansion into various markets and we regard the E-House market as very appealing, as we’re able to combine our total product offering into a complete

E-House solution. This technology is relatively new in South Africa, but it is becoming more attractive than the traditional containerised substation solution primarily because these E-House units can be manufactured to customised dimensions. “Traditionally, Shaw Controls has been involved in supplying containerised substation solutions, but industry in Africa is definitely gravitating towards custom-built E-Houses that suit customers’ requirements in terms of the amount of equipment that can be fitted into it, which often exceeds the limits of a container.” Work on the seven E-Houses

Inclinometer for rough and tough conditions

nstrotech, local distributor of process control instrumentation and specialised systems, is pleased to announce the launch of the new SIKO Inclinometer IK360L, capable of working under the roughest and toughest of conditions. The unit conforms to protection classes IP68 and IP69k and is protected against access with a wire as well as being dustproof. It is also protected against permanent immersion and infiltration by water under high-pressure and vapour steam cleaning (i.e. road vehicles). The unit is housed in a PBT fibreglass, reinforced casing and is easily installed with a 3-point mount. The unit compensates for temperature, operating between -40° to +85°. The unit can also operate within a lateral devia-

began in March 2013 and the final units will shortly be despatched. Shaw Controls has designed, procured and installed all the electrical equipment contained within the E-Houses including medium voltage (MV) switchgear, MV transformers, low voltage (LV) motor control centres, LV variable speed drives, HVAC, fire detection and suppression, PLCs and cabling.

tion of +/-45°. SI K O ’ s Inclinometer IK360L features a compact oneaxis inclinometer with integrated Position measurement of the shovel for dredgers electronics and a system accuracy of +/-0,5° (-10…+40°C). One rement direction. axis is 0 - 360°; two axis: +/- 80°. The SIKO’s Inclinometer IK360L finds resolution: 0,01° and has a response application in mobile automation; time sensor of 10 ms (without filter). ensuring the horizontal position of The different interfaces available are the workman’s basket or fire brigade RS-232+I, RS-232+U (0…10 Volt) or engines; monitoring of the levelling of CANopen (bus-compatible). vehicles with tracks (construction) to Programmable parameters are avoid overturning and position measResolution, Preset, Software filters. It urement of the shovel of dredging also features a ‘Teach-In’ function that vehicles Enquiry no: 83 measures range, zero point or measu-

Easy to operate new ultrasonic sensors ood process reliability and ease of G operation are two important criteria demanded of industrial systems. With the new Ultrasonic Sensor range, Wenglor Sensoric has succeeded in optimizing both of these requirements. Equipped with simple, clear-cut controls, theses sensors are child’s play to install, configure and operate without neglecting the strict demands placed on secure process sequences. The Ultrasonic Sensors function on the principle whereby pulsed ultrasonic waves are transmitted by the sensors at a certain frequency using air as a transmitting medium, and are reflected back when they strike the object. The sensors then evaluate transit time of the ultrasonic waves. Device parameters are configured directly at the sensor by means of external teach-in or via IO-Link. When previously specified switching points are reached, the outputs are switched. Measured values can be read out as standard voltage or current signals (0 to 10 V or 4 to 20 mA), or in digital format (IO-Link). In addition to ease of use, the Ultrasonic Sensors are above all distinguished by reliable performance in dusty, oily and steamy environments. In order to cover larger surface areas with several sensors, Wenglor offers synchronous operating mode by means of where pulsed sound waves are emitted simultaneously by all of the sensors. By contrast, the sensors are activated alternately in the multiplex operating mode so that neighboring units do not influence each other. The rugged IP67 housings are available in plastic or stainless steel versions and can be supplied in various designs and sizes and working ranges. Enquiry no: 84

Measure

The Real World

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Using Specialist Software and Computing Platforms

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CheckIT Systems specialises in Instrumentation, Measurement and Control and offers customised solutions by leveraging its alliance partnership with National Instruments. Call us on 0860 106 261 for a consult

Many of these products were supplied by Zest WEG Group’s parent company WEG in Brazil. The E-Houses are being transported to two different locations. All seven units have been road freighted from Johannesburg to Mozambique under abnormal load conditions. Enquiry no: 82

February / March 2014

KZN Industrial & Business News

ENGINEERING & ALLIED SUPPLIES

Do not be ‘floored’ – Safety is Vital

hen it comes to gratings and stair treads, the design specifications and choice of material are critical factors not only in safety, but also in ease of maintenance and on-site installation costs. Taking any short cuts, can lead to unforeseen delays in project completion. This is the view of Dodds Pringle, Managing Director of Vital Engineering, a company which specialises in the manufacture of steel and fibreglass gratings, stair treads, pressed floors and safety handrails. “Effective design not only impacts safety, which is top of our agenda, but it also affects other, less obvious issues, such as ease of upkeep and a smooth installation process on site,” he points out. “In many steel buildings, it is easy to run

piping and ducting through the floors because holes and passages can easily be cut out in the grating floors. However, if there is a discrepancy between the size of the grating opening and the flange (which invariably is larger in diameter than the pipe), the factory-shaped galvanised cut would have to be re-shaped, using site installation resources, amounting to expensive hidden installation costs.” A more practical alternative would be to run all the piping and the electrical cabling on the outside of the building and feed these underneath the floor support beams or through cellular support beams. “This would centralise the maintenance areas in which the client’s contractors have to work without interfering with the ongoing operation of the plant and the initial construction. It would reduce considerable downtime, as installation of flooring can be easily undertaken with less re-work and changes, and in modular units which make for more cost-effective and efficient

transportation and storage.” Vital Engineering provides a full consultation service, drawing their customers’ attention to potential pitfalls and hidden costs, as well as presenting them with a vast array of options when it comes to materials and finishes. The company can list power plants, petrochemical plants, process plants, water treatment plants, the mining industry and a number of structural and civil engineering projects among its many clients. “We place great emphasis on designing for safety, using only the highest grade steel such as WA355. We also pride ourselves on continually introducing new products and finishes to market to suit individual design requirements,” Pringle says. Some of the company’s latest innovations include new ‘sunscreen’ expanded metals in lighter materials which add considerable cooling efficiencies, as well as a new range of fibre-

glass gratings that can be used for light-weight glass-clad building cleaning walkways, building curtain walling, gates, grillages, wall infills, mini-meshes for harbour wharfs, decking, pool surrounds and water run-off/cabling trenches in shopping centres and office buildings. Enquiry no: 85

All-round monitoring for rolling bearings

hrough the intelligent interconnection of its products, Schaeffler Industrial Aftermarket will make it possible in the future to combine the monitoring and condition-based lubrication of rolling bearings in one innovative system that combines grease and vibration diagnosis with a lubricator that is activated by the monitoring devices. The intelligent interaction of monitoring and lubrication systems ensures reliable machine availability and also saves resources. When a rolling bearing has a low consumption of lubricating grease, its operating life is increased and the costs arising from expensive onsite maintenance work are dramatically reduced. Until now, it has not been possible to reliably analyze the lubricating grease in rolling bearings during operation. Schaeffler is setting a new standard here with the FAG GreaseCheck. The sensor reliably detects whether the condition and quantity of the grease is sufficient and sounds the alarm as soon as any changes occur. In addition to the conversion from time-controlled to requirement-con-

trolled lubrication, this also makes it possible to take action before the bearing is damaged due to insufficient lubrication. When this is combined with the FAG SmartCheck – the compact system for measuring vibration and other parameters – the rolling bearing is completely under control. The final piece of the comprehensive monitoring puzzle falls into place with the integration of the new FAG CONCEPT 8 lubricator. This has eight outlets that can be activated by the condition monitoring devices and, depending on

its requirements, supply the rolling bearing with the Arcanol lubricant developed specially by Schaeffler. Schaeffler’s monitoring experts will be on hand to provide support in installing the new complete system, which became available on the market during the second half of 2013 onwards. The characteristics of the lubricants are also decisive when it comes to achieving a long operating life for rolling bearings. FAG’s Arcanol rolling bearing greases were designed and tested for a wide range of applications and have better characteristics than normal greases in all areas. The FAG GreaseCheck grease sensor was specifically developed for the Arcanol grease range. Four parameters can be detected using the optical infrared reflection method: Water content, cloudiness, thermal or mechanical wear, and temperature. The intelligent evaluation electronics generate an analog signal from these values that keeps the operator constantly informed of the condition of the grease.

Enquiry no: 86

Setting the standard for turning and milling

t the beginning of March, Sandvik Coromant introduced new insert grades for steel turning and cast iron milling with Inveio; the technical breakthrough in material science that provides inserts with exceptional wear resistance and tool life. In today’s manufacturing, predictability is becoming increasingly important. Production that runs smoothly, without unexpected interruptions, opens the way for secure unmanned production and high machine utilization; a cornerstone for profitable production processes. Following the successful introduction of the insert grade GC4325 in October 2013, Sandvik Coromant has now introduced the new grades GC4315 and GC3330. All three

grades feature Inveio that brings endurance, predictability and long tool life to the machining process. The performance of these grades is made possible by the Inveio uni-directional crystal orientation. Normally, the crystal orientation in inserts’ CVD alumina coating is random. The breakthrough came when

Sandvik Coromant found a way to control the crystals, making them all line up in the same direction – towards the top surface. These tightly-packed crystals create a strong barrier towards the cutting zone and chip. The result is grades with incredible wear resistance and cutting edges that stay in shape for longer. The long, predictable tool life of GC4325, GC4315 and GC3330 enables secure unmanned production with high metal removal rate. GC4325 is the first choice grade for steel turning. When GC4325 reaches a limit in metal removal rate due to high speed and long time in cut, GC4315 withstands the high cutting temperatures that occur. GC3330 is the first choice grade for milling in cast iron materials.

Enquiry no: 87

February / March 2014

KZN Industrial & Business News

ENGINEERING & ALLIED SUPPLIES

Electrostatic spray system T T he Model 102000 AccuJet Electrostatic Spray System, available through Monitor Engineering, improves chain lubrication while greatly reducing oil consumption and conveyor downtime. The patent-pending system consists of a dedicated control panel, up to four electrostatic spray nozzles with an injector pump for each nozzle, a 16 litre oil reservoir and a pressure regulator/filter/pressure switch assembly. The electrostatic nozzles apply chain lube to the key lubrication points on the chain with extremely high transfer efficiency, saving oil, reducing chain breaks and limiting the downtime often associated with chain-driven conveyors. The system’s low-flow injector pumps can deliver lubricant to as many as four electrostatic spray nozzles simultaneously. Pumps can be individually adjusted to deliver the precise volume of lubrication required to

each spray station and can be easily added to the system after initial installation. This offers complete uniform lubrication of critical areas between the pin and bushings and extends chain life. It also eliminates oil mist and creates a safer w o r k environment for operators while reducing the potential for product contamination from process lubricant. The high transfer efficiency reduceds oil usage and minimises cleanup caused by overspray. In addition, the product is 100% pre-tested

and pre-programmed for quick installation on site. Electrostatic spray technology is based on the scientific principle that “opposites attract.” In electrostatic spraying, a negatively charged liquid coating is attracted to a neutral, grounded target. The physical attraction of the liquid to the target pulls the coating to the chain surface, providing a transfer efficiency of over 90%. Using this technology, overspray is also virtually eliminated, reducing clean-up and improving the work environment. Typical applications include oil coating, chain lubrication, bearing and roller lubrication and deco pin chain lubrication. Enquiry no: 88

Duplex roller with top operator comfort

he high level of operator comfort offered by the LP6500 Duplex Roller is a direct result of Atlas Copco’s continuous focus on ergonomic design. Recently, in a test performed by

the independent technical inspection organization TÜV Nord, the LP6500 was compared with two similar duplex roller models from other manufacturers. The test provided confirmation that

the LP6500 has lower vibrations in the handle and lower machine noise than the other machines tested. In the vibration test the LP6500 showed a hand-arm vibration level of only 4.14 m/s² in the top handle, while one competing roller was measured at 7.01 m/s2 in the direction handle. Thus the hand-arm vibration level in the handle of the LP6500 is 2.87 m/s² lower, which means considerably less strain on the operator during a working day. In the noise emission test, the LP6500 showed a sound pressure level of only 89 dB(A), which is 3 dB(A) lower than one of the competing machines, and 6 dB(A) lower than the other. The LP6500 provides high compaction efficiency on thin granular soil layers, such as sand and gravel. When compacting silt, the compaction effect depends largely on water content and the LP6500 is most effective on thin layers. On asphalt the end results are excellent and the LP6500 is well suited for smaller jobs in areas such as pavement construction or repair, narrow roads, playgrounds or parking lots. Enquiry no: 89

Four functions in one

egrand’s Starfix ferrules, cable crimping tools and applicators, which form part of the company’s comprehensive cable management system, are designed for new installations and renovations in commercial installations, offices and domestic environments. “The outstanding feature of this tool is that it efficiently performs four functions in one operation, offering time savings of more than 50 % compared with traditional tools that complete the same tasks,” says Luk Ivens, general manager, Legrand Southern Africa. “The Starfix crimping tool cuts, strips (with a side thrust), twists and automatically crimps each Starfix ferrule onto the cable. “This easy to operate tool has a fully adjustable wheel which is set to the cross section of the cable. The cable is then cut to the required length, automatically stripped and then twisted by tightening the tool and pulling the cable to remove the insulation. Ferrules, with an insulating flange, are then dispensed and crimped. The flexibility of this tool enables right and left handed users to easily perform these functions.” For immediate recognition of the appropriate cross-section of ferrules, they are colour matched with applicators which have a transparent, remov-

able protective cover. Ferrules are manufactured in strips for simultaneous separating and crimping. For easy handling and convenience on site, they are supplied in sachet or box packing. As the last remaining ferrules are held firmly in the box packing option, there is never any wastage. Accessories include cutting and crimping blades, as well as fixing components. New to the range are Starfix applicators which are available in yellow (for ferrules with cross sections between 0,25 mm² and 0,34 mm²) in red (for ferrules with cross sections

between 0,5 mm² and 2,5 mm²)and orange(for ferrules with cross sections between 4 mm² and 6 mm²). Starfix ferrules, with insulating flanges provide an equipotential link for all the strands of a flexible conductor. These ferrules can accommodate cables in the singlein-strips format, or in single individual sachet packing, in cross sections from 0,25 mm² to 6 mm². Single individual ferrules in box packing are colour coded in brown, white, black, red and blue. Double individual ferrules are available as 2 x 0,75 mm², 2 x 1 mm², 2 x 1,5 mm² and 2 x 2,5 mm² Empty colour coded refill applicators are designed for user convenience, reducing the need for re-loading. Legrand also supplies this cable marketing system in kit form. Kits consists of a crimping tool for crimping up to a 6 mm² ferrule and various individual ferrules between 10 mm² and 50 mm². A tool box for on site use, containing Starfix, Cab 3 and Duplix marking systems, is also available from Legrand and its national distributor network. A technical advisory and support service Enquiry no: 90 is offered.

he South African division of Bosch Power Tools has expanded its Compact Generation line of DIY tools, by launching a new range of PWS angle grinders to the local market. The new range includes the PWS 700-115 and the PWS 850-125 model angle grinders. Bosch Power Tools SA senior manager Juergen Lauer notes that the new range of angle grinders have a smaller grip circumference and a lightweight design. “Weighing just 1,7 kg and 1,8 kg respectively, the new PWS angle grinders offer improved user comfort in a number of applications.” The PWS range of angle grinders fall within the Universal class of Bosch’s Compact Generation.

New range of angle grinders “They have an adjustable protective guard, which can be adjusted without the use of a wrench, and a spindle lock allowing for easy disc change. The PWS range of angle grinders also come with a new patented sealing at the rear bearing, which reduces vibrations.” The PWS 700-115 angle grinder boasts 700 watts of power and is suitable for small to medium tasks, such as cutting, grinding and brushing metal and stainless steel. Enquiry no: 91

February / March 2014

ENGINEERING & ALLIED SUPPLIES

Measuring tensile forces and kgs

ecker Mining South Africa’s range of load indicating devices includes the high precision Dynafor LLX2 instrument, which accurately measures tensile forces (N) and determines the exact weight (kg) of hanging loads. “The unit – which encompasses the latest technology in industrial dynamometry - consists of a sensor and removable display. For enhanced flexibility, the mobile display attaches securely to the sensor unit or can be hand held for remote measurement,” says Charlotte Megannon, product manager for Becker Mining South Africa. “High endurance has been critical in the design of these new devices. The sensor offers between 300 and 1 000 hours, depending on functions and 3 000 hours on standby. The display unit ensures 48 hours in use. “Other important features of this new series include a precision of 0,1 % and the latest radio technology for enhanced performance. The Dynafor LLX2 has a 2,4 GHz frequency band which provides a high operating range of 80 m. The wireless link enables this device to be used in any environment where a number of different devices are simultaneously in operation, with no risk of interference.”

The series, which is available in six capacities between 0,5 T and 6,3 T, has an IP66 index protection rating that enables use indoors and outdoors. This robust unit has also been designed for excellence shock and moisture resistance. The operating temperature range is between -20°C and +40°C. Intuitive commands enable fast access to various functions. For enhanced flexibility, up to four sensors can be associated to four displays during operation. A PC link connection kit, via a USB interface, enables advanced processing of measurement data. A range of fastening systems designed specially for the Dynafor means compatibility with traditional shackles and with accessories for all stand chains. The Dynafor range complies with stringent international specifications on electromagnetic compatibility. The Dynafor range is ideally suited for use in diverse industries, including mining, shipping, construction, engineering, transport and forestry. Specific applications include testing of lifting equipment, stock taking and loadchecking goods in and out.

Enquiry no: 92

KZN Industrial & Business News

One of a kind service centre

roviding access to some of the world’s most renowned brands is a key part of Renttech South Africa’s services to customers. The company’s distributorship of the Harris range of metalworking products is helping to realise the company’s goal of becoming the leading Southern African supplier of welding and construction-related equipment. The Harris Products Group, chose Renttech South Africa to distribute its product range in SA in September 2012 and the new Harris service centre at Renttech’s premises in Wadeville - the only one of its kind in South Africa. - offers local clients many benefits when it comes to convenience and accessibility to service and products. Gerrit van Zyl (pictured), Managing Director of Renttech South Africa, explains: “Our new Harris service centre will bring our customers a much wider product offering, improved stock-holding and increased availability. “We will offer the same service standards, based on the international ISO certification, as the Harris Group globally, and all products will be repaired and refurbished to Harris’ strict standards.” Harris’s relationship with Renttech is based on a highly synergistic partnership which will leverage off Renttech’s expanding footprint. “The market sectors we serve in South Africa mirror those of Renttech South Africa – particularly mining, petrochemical, rail, ship building and repair, paper and pulp, food and beverage and heavy industry.” “Our product reliability is well-known across all these different market sectors, having served the South African market for 60 years.” Harris is very confident of Renttech South

Africa’s professionalism, technical abilities and expertise to support our products in this country,” says Fabio Pedracolli, Managing Director of the Harris International Products Group The Harris Products Group, a whollyowned subsidiary of the Lincoln Electric Company (a world leader in the design, development and manufacture of arc welding products, robotic welding system, plasma and oxy-fuel cutting equipment) manufactures a range of products used in the brazing, soldering, welding, cutting and gas distribution industries. These include torches, pressure and flow control equipment for welding and cutting, as well as laboratory, laser and high purity gas applications. These products are carefully designed and tailored to suit various applications and industries. Renttech South Africa, which offers the largest fleet of rental welding equipment in Southern Africa, provides industry with the rental and sales of a wide range of welding, power generation, lifting, rigging and construction-related equipment, and consumables. “We are confident that our repair centre, with a combination of Harris engineering and product management, and Renttech South Africa’s technical expertise and superior inventory management will provide a new level of customer service. Based on Harris’s commitment to best manufacturing practices, we now have the ability to offer extended warranties and a guarantee of products of uncompromising safety and quality,” van Zyl concludes. Enquiry no: 93

Flame detector saves time in critical situations

V13792

n advanced multi-spectrum flame detector designed specifically for industrial applications has been launched by MSA Africa - a global leader in the development, manufacture and supply of sophisticated products that protect people’s health and safety.

Reliability Coupled with Lowest Total Cost of Ownership. Falk Steelflex Coupling Steelflex is known for proven performance and durability in critical applications. The versatile design offers superior damping and reduces peak torque loads by as much as 30% for ultimately lower wear on connected equipment components. The ‘replace-in-place‘ design reduces element change-out time. Available in a comprehensive range of bore, speed and torque capacities. Tel: +27 11 418 4000 info.vtza@voith.com www.rsa.voithturbo.com

The MSA FlameGard 5 multi-sensor detector identifies fires by monitoring the ultraviolet (UV) and infrared (IR) spectral ranges, making it highly immune to false alarms caused by lightning, arc welding, hot objects and other sources of radiation. According to MSA Africa product manager for gas detection products, Robbie Taitz, the detector is suited to numerous applications, ranging from aircraft hangars and chemical plants, to compressor stations, gas turbines and fuel loading facilities. “The MSA FlameGard 5 detects fires and provides alarm outputs directly from the unit, while maintaining its false alarm immunity. What’s more, it provides more data, increased detection distances, faster response times and better performance under various environmental conditions, making it suitable for a wide range of applications,” he explains. Another major benefit is the continuous optical path monitoring (COPM) feature, which checks the optical path integrity and the unit’s electronic circuitry once a minute. Taitz adds: “The COPM self-test feature eliminates the risk of inaccurate performance, thereby ensuring greater peace-ofmind with regards to safety in an emergency situation.” The MSA FlameGard 5 detector also features an RS-485 serial output with ModBus RTU protocol, which enables the linking of up to 128 detectors in series, or 247 with repeaters. “For improved turnaround times in emergencies, the ModBus and HART user-interface ensures full status and control of all detectors located across a site, from one centralised control room,” Taitz concludes. Enquiry no: 94

February / March 2014

KZN Industrial & Business News

COMPANY & PRODUCT NEWS Entrepreneur Finding the world’s most competition fuel-efficient driver

takes winner to new heights I n light of the recent launch of the 2014 Sanlam / Business Partners Entrepreneur of the Year competition, which aims to honour, benefit and uplift local entrepreneurs, William Duk (pictured) of Plantation Shutters and overall 2012 Sanlam / Business Partners Entrepreneur of the Year, shares his experiences and discusses how his participation in the competition is still having a positive impact on his business. Duk says that winning the award was a very powerful affirmation and acknowledgement of all the hard work that everyone in the business had put in over the six year period since reviving Plantation Shutters. “There was an extra degree of pride or confidence that suddenly everybody had, based on the credibility that something like this award brings. This, for me, was and has been the most significant aspect of the award.” Duk’s entrepreneurial success began with a classic stroke of luck. He was in the process of purchasing an industrial building just outside of Cape Town when he stumbled upon a small bankrupt company operating within the premises, and on the spur of the moment, made the decision to take over the business. Within five years of purchasing Plantation Shutters, a business that designs, manufactures and installs adjustable window and door shutters, Duk doubled the work force and increased its turnover tenfold. The various positive spin offs from winning the competition has ensued a further 30% growth for the business in 2013. “The credibility of the award has had a positive impact in offering peace of mind to clients choosing to work with Plantation Shutters. When clients are parting with a 50% deposit for a premium product, the award further endorses their purchasing decision, which is definitely a good thing.” He says that the publicity that the award generated for his business has also provided much more than any marketing budget could have ever achieved.

Green sense concrete technology

ASF now offers its Green Sense® Concrete technology for the resourceefficient production and processing of concrete in Europe as well. Green Sense Concrete is a service package from BASF that helps manufacturers improve the performance characteristics of concrete such as resilience, workability, durability and environmental friendliness. The package comprises three components: The optimization of the concrete mix design by BASF experts, the use of hyperplasticizers from BASF such as MasterGlenium®, and an eco-efficiency analysis of the concrete mix. The analysis serves to ascertain economic and ecological performance criteria of the concrete in comparison to traditional concrete mix designs. The use of the Green Sense Concrete technology has for example led to savings of around 15,800 tons of CO 2 equivalents and approximately 25,400 megawatt hours of energy in the construction of the new One World Trade Center in New York City compared with a conventional concrete mix design. In this way, BASF provides solutions for urgent challenges of the construction industry such as the high share in primary energy consumption, in greenhouse gases and in fine dust emissions. The Green Sense Concrete technology was first used in Europe in the construction of a new BASF office building in Ludwigshafen, Germany. The seven story building has a total area of about 35,000m² and is scheduled for completion in 2015. It will provide more than 1,400 additional office workspaces. BASF aims for gold standard certification from the German Enquiry no: 96 Sustainable Building Council.

Apart from Plantation Shutters becoming a thriving business, another business opportunity presented itself to Duk a few months after winning the competition which enabled him to maximise the mentorship programme which formed part of his prize. The mentorship opportunity enables entrepreneurs to seek valuable advice from a business leader in a similar industry in order to further develop and drive their business. This new business opportunity presented itself when Duk was approached a couple of years earlier to assist a business that supplies valves to the mining and related industries across Africa. While a buyer was found, this deal fell through towards the end of 2012 and presented Duk with the opportunity to purchase the business himself. One of the hurdles to this opportunity was that the business was turning over well in excess of R100 million and the sellers wanted R35 million. “I didn’t have a cent spare cash as I was still busy paying the original founding partner in Plantation Shutters, who I bought out two years ago.” “I also didn’t particularly want an equity partner as that would have been a very expensive path.” This predicament resulted in Duk contacting Business Partners Limited to claim his mentorship package. “While the amount needed was outside of Business Partners non-equity based lending criteria, I was put in personal contact with FNB who are very aggressive in the debt based leveraged financing space. Only 10 days later I put in an offer for R35 million which was accepted subject to due diligence, which was primarily around being able to raise the money.” To enter the 2014 Sanlam / Business Partners Entrepreneur of the Year, please visit www.eoy.co.za Entries close 16 June 2014. Enquiry no: 95

egistration has now opened for the Drivers’ Fuel Challenge 2014 – Volvo Trucks’ global competition of fuel-efficient driving. The Drivers’ Fuel Challenge is open to all professional truck drivers, irrespective of brand. The final will take place in Sweden on 19 September, 2014. The Drivers’ Fuel Challenge has been arranged in different forms – global or regional –annually since 2009. Its popularity has grown since its inception and the most recent global competition in 2011 attracted around 3 600 participants from 22 countries. This is the first time that a South African driver has a guaranteed spot in the World Final in Sweden. “Fuel cost is a heavy burden for most haulage companies. However, an improved driving style can result in considerable cost savings. With the Drivers’ Fuel Challenge we want to highlight this fact and encourage truck drivers to adopt a more fuel-efficient way of driving,” says Philip Phasha (pictured), Project Manager for the Drivers’ Fuel Challenge 2014 in South Africa. The potential benefits of driving in a fuelefficient way are considerable. Volvo Trucks’ own research shows that by using accredited services for individual followups on fuel consumption, together with driver training, it is possible to reduce fuel consumption by around 10%. Participants will not only be tested in actual fuel consumption but also in fuel-affecting

driver behaviour such as anticipation, braking, as well as engine and gearbox utilisation. This testing will be conducted under realistic conditions in which the drivers must maintain productivity in a safe and responsible manner. The South African rounds will take place on the following Saturdays: 24 May in Cape Town, 7 June in Durban and the 14 June in Johannesburg. The national competition will be held on the 21 June and will also take place in Johannesburg. Participants may register from January 30 to March 30, 2014 To register, please send an email with your name, surname, email address, company name, telephone number, as well as a copy of your PDP license to Info.MarketingSA@ volvo.com

Lifting in Explosive Environments

Enquiry no: 97

February / March 2014

company & product News

KZN Industrial & Business News

Creating a productive work environment W Trade and Industry Minister, Dr Rob Davies visited Bell Equipment’s manufacturing facility and head office in Richards Bay at the end of January where he toured the factory and celebrated the handover of the company’s 50 000th vehicle.

hat is Productivity? Productivity has many interpretations, a few of which are that it is a state of mind, that it involves continuous improvement on what is happening today, that it is a motivation to improve on yesterday’s performance and to do even better tomorrow, that it is a mindset to improve on the current situation regardless of how well it works and that it is the will to apply new techniques and methods. Irrespective of how we choose to define productivity. In reality, it is very simply the following relationship between outputs over inputs. This is applicable to any company, corner café, an individual, community, province, and to South Africa as a whole. Outputs are the end result of the process, whether it is “widgets” or Profit. The Inputs can be the raw materials being used to process the widgets or human resources for example, but the reality is that anything and everything used to produce the “widget” is the Input. Productivity itself depends on factors such as: • Efficiency. This basically refers to the ability of a Resource (Human or Machine) to complete a given task correctly, within acceptable Quality norms without any waste of resources and within the time allocated for the completion of the task. • Utilisation. Utilisation refers to the optimal use of both Machinery and Manpower as the main resource being measured during the period allocated for it to be used in completing the task. • Quality: Quality is a measure of excellence (free of defects) brought about through the strict maintaining of standards that are able to achieve the Product being produced to specific customer requirements. • Wastage: Wastage refers to the use of resources during the conversion process (Input to Output), with the result that some of the resources used do not end up as a finished product of the correct quality. This can be any of the following: Raw material, time wastage, space constraints, and excessive energy usage resulting in a waste of money. • Management Support: This is vital in any organisation.

• Communication between Management and the Workforce (both up and down) is important and is usually handled through daily Goal Alignment Meetings. Management support of any Productivity initiatives will ensure cost saving benefits. In order to improve Productivity it is important that the Business knows where they currently are. The use of Measured Information to create a Benchmark as a start point is vital to

begin the Continuous Improvement Process. Once this has been done the Business can measure itself versus the previous Benchmark to determine where they are succeeding as well as failing. Another area that can be looked at is the manning levels of the Organisation. Too many staff, and you have wastage, too little staff and targets will never be achieved. A balancing act is important here. Data must be collected and a database created which will assist Businesses to determine the levels of staff required. This calculation must take into account the various peaks and valleys of the business. Correct manning levels will ensure that the size of a work team required to perform a given process or operation in a given time will result in no wastage of human resources. Some of the aspects that need to be taken into account in determining the correct manning levels are economical staffing of machines, whether automatic, semi-automatic or manually controlled, the number of machines that one operator can monitor and the balance of work on assembly lines so that bottlenecks are avoided and waiting time reduced Planning and control is another vital aspect of improving Productivity. It is important that the Production Process takes the following into account:

• accurate planning of materials and resources per task • accurate machine and department loading • deciding economic batch sizes • assessing manufacturing capacity • closer and more effective control of movement between processes or departments i.e. Work in Progress Operator Performance is also a factor which is a vital part in wanting to improve Productivity. Work measurement can set standards that determine the operators performance compared to the standard and thereby can indicate whether further or re-training is necessary. Controlling of all Input Costs is also important. Measures need to be implemented by which Management can measure the effectiveness of a department and standards for labour, materials and overheads must be set and compared to actual as a very reliable way of comparing between two or more alternatives. Incentive Schemes can also increase Productivity if done correctly and transparently. Work measurement can provide data which will provides the most accurate basis on which such schemes can be constructed, as most Incentives will be paid if Outputs of the Worker exceed the targets set, whereas such targets are derived from Work Standards. Finally, in order to improve Productivity, the following myths also need to be addressed. • “Productivity improvement takes away jobs” • “Productivity means only working harder” • “Productivity is only applicable in a factory environment” • “Productivity and its related activities are a waste of time and energy” • “Productivity only benefits employers” • “Productivity is the responsibility of labour only” The way forward is that we need to adopt a productive culture with a mind set and a set of habits where everyone and every effort contributes to improving and building up ourselves, our economy and our nation”. Contribution by: Mervyn Mathee The Productivity Company Enquiry no: 98

Oxy-acetylene kits a hit

I keep my ﬂeet real. I keep it Cat

KEEP IT REAL. KEEP IT CAT®

You have to push every day. To meet tomorrow’s deadline. To secure the next contract. To stay ahead of the competition. No matter what challenges lie ahead, Caterpillar and Barloworld Equipment are committed to bringing you machines, solutions and support to help your business keep pushing forward. BUILT FOR IT.

For more information contact our call centre on 0800 21 22 48 or visit www.barloworld-equipment.com

© 2014 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, BUILT FOR IT, their respective logos, “Caterpillar Yellow,” the “Power Edge”trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

he heavy industrial T market is recognising the value of the

Afrox Service Level Agreement (SLA) attached to its Afrox BlueBox and Afrox RedBox heavy duty oxy-acetylene kits. “Beyond being premium ISO/SANS approved equipment that has been specifically packaged to perform in rugged working environments such as mining, construction, shipbuilding, quarrying, scrap handling and heavy fabrication,” says Afrox’s Lourens le Roux. “Under the SLA, each kit and each item of equipment it contains bear a dedicated serial number to ensure traceability and user accountability, minimising equipment abuse, loss and theft. The serial number is logged onto an Afrox database to ensure timeous servicing and replacement of elements, as well as to log equipment abuse and frequency of use. The Afrox BlueBox contains selected elements of Afrox’s popular Saffire Legend 916 range of heavy duty cutting equipment, torches and regulators including an acetylene cutting torch capable of cutting up to 450 mm plate with an 8F cutting tip. The Afrox RedBox comprises gas equipment selected from other areas of Afrox’s Saffire gas equipment series, with 3/8” outlet connectors and fittings. This set features the Saffire universal torch capable of cutting up to 300 mm thick steel with a 3,2 Anm6 cutting nozzle, as well as SANS 2503 approved Saffire multi-stage regulators, incorporating “set and forget” technology that delivers conEnquiry no: 99 stant pressure.

February / March 2014

KZN Industrial & Business News

company & product News

Versatility and mobility L aunched globally from the fourth quarter of 2013, Caterpillar’s new B-Series utility compactor line-up builds on the success of the previous generation and comes to market in a nine model line-up to compete in the 1,8 mt to 5 mt size class. B-Series units are manufactured at Caterpillar’s Rantigny production facility in France. “Caterpillar’s primary design goal on the B-Series is to enable contractors to achieve even more efficient compaction,” explains Barloworld Equipment paving product manager, Johan Hartman, “with multiple vibration frequencies plus ballast options on specific models to provide bestin-class versatility on varied job sites in either granular or asphalt applications.” Popular B-Series units for the southern African market include the CB14B, CB24B and CB34B models. The vibratory system on these units provides a good balance between frequency and amplitude to meet diverse asphalt pavement applications that include urban streets, paths, parking lots, driveways, patching and shoulder work. The CB14B has a default high frequency of 70 Hz; whilst the CB24B has three frequency selections, namely high (63 Hz), middle (52 Hz) and

low (42 Hz). The CB34B in turn has a high and low frequency selection mode of 55 Hz and 48 Hz. Standard operating weights for the CB14B, CB24B and CB34B are 1 520 kg (with a 1 000mm drum), 2 723 kg (1 200 mm drum) and 3 699 kg (1 300 mm drum) respectively. Mid range extra weight machine options are also available, examples being the Cat CB24B XT and CB34B XW (with wider 1 400mm drum width). Optional ballast configurations include the Cat CB34B and CB34 XW models, which provide the flexibility to add and remove weight on the drums, as required, for varied compaction requirements. Vibratory selection on most models includes front drum only, rear or both drums. Each drum is fitted with front and rear scrapers that are spring-loaded, retractable and self-adjusting. On the go, the dual-drum drive powertrain provides continuous full-drum traction on soft base materials, uneven surfaces and steeper grades. Meanwhile, the rounded drum edge prevents cutting into the mat. For final finishing, Caterpillar also

101 Brands – and counting

fields two combi rollers, the Cat CC24B and CC34B, both of which come standard with rear pneumatic tyres and a front vibratory drum roller. “Pneumatic tyres provide a kneading action for a tight mat finish, creating high ground pressure that penetrates deep into the lift,” Hartman continues. A distinctive feature on the new B-Series is their excellent drum-edge visibility due to the sloped hood, longitudinal engine mount and narrow frame design, which improves control for better coverage and compaction results. A maximum 50 mm drum offset feature enhances control near curbs and obstacles while providing more coverage. Engine power on demand provides the push needed on grades, with units driven by either a Cat C1,5 or Cat C2,2 unit depending on the machine size. (The exception is the Cat CB14B, which is fitted with a Kohler engine.) Enquiry no: 100

Not many people are aware that Konecranes, which has a branch in Pinetown, owns over 100 well known crane and hoist brands worldwide. Among them are Morris Material Handling, Shepard Niles, Cleveland Cranes, Euclid and Kaverit Cranes & Service. In addition the company currently has over 430 000 cranes under service contract in its 636 branches in over 50 countries. 25% of these are Konecranes with the remaining 75% competitive brands that are not owned by Konecranes. “As the biggest crane and hoist service company in the world Konecranes has huge buying power, resulting in competitive prices and the ability to supply parts for all makes of cranes and hoists”, says John MacDonald, Service, Sales and Marketing Director of Konecranes Southern Africa.

Konecranes has 14 Parts Distribution Centres worldwide, including one in Johannesburg. “We strive for a 24h turnaround for parts as well as offer a 24h service to our customers”, MacDonald says. Konecranes has six branches around the country, apart from its head office in Johannesburg. These are in Witbank, Durban, Port Elizabeth, Cape Town, Alrode and Klerksdorp. More are planned to open later this year. Enquiry no: 103

. .

Earthmoving financial solution

JS Projekte’s recent acquisition of a Doosan 30 ton articulated dump truck was made possible through a finance solution by Fintech, leader in asset rental finance. This enabled them to deliver against their 5 year contract with Mintails Mine. Fintech’s recent decision to expand their financing options into specific market sectors has allowed for the leasing of heavy duty industrial equipment. “We needed the finance for the truck in a short period of time and we were impressed at how quickly the deal with Fintech was finalised. We have the opportunity to develop with Mintails Mine, now that Fintech is our finance partner. Due to Fintech’s efficiency, professionalism and outstand-

ing service delivery, we are already negotiating a second heavy duty equipment lease transaction,” said Erika Scherman, Technical Financial Accountant at EJS Projekte & EJS Earthmoving. Glen Chistopulo, CEO of Fintech

Crate washing program

ncreasingly, plastic crates are used to receive, store and transport raw products from farms to plants and from the food and beverage processing plants to supermarkets. Small volumes of crates can be cleaned by hand scrubbing or via a hand held pressure washer. However, the plastic crates are difficult to clean properly as they are antistatic which tends to attract dust and dirt. Also food and beverage breakages and spillages tend to dry on the crates which can be difficult to remove. The most practical method is by using a crate washer which subjects the crates to an extended hot water detergent wash followed by a rinse. Branson Chemicals has developed Ultrasol and Rinse Dry which is an advanced program specifically formulated for use in plastic crate washing machines, ultrasonic baths or spray cabinets. Ultrasol easily removes baked or encrusted dirt and food soils at low concentrations without damaging the plastic or the decorative printing on the crates. The injection of Rinse Dry into the final rinse leaves an antistatic film on the surface that discourages soil re-deposition and helps dry Enquiry no: 102 the crates quickly.

said, “Through our latest interactions with EJS Projekte, we are motivated to refine our knowledge of this industry sector even further. Heavy duty equipment is costly and we free up working capital for businesses that would like to accept projects for which they have the requisite skills, but not the necessary tools.” Fintech has identified the mining and construction industries as a sector that could benefit from their tailored financing packages. They are able to work directly with end users or with their chosen suppliers, such as heavy duty equipment businesses, enabling companies to run at their best and in this case where it counts the most – to literally move earth. Enquiry no: 101

Nice rack? Universal Storage Systems, through the use of its own research technology and highly trained engineers, has a reputation of solving the toughest industrial shelving problems. By combining our knowledge with that of international partners, Universal is one of South Africa’s leading manufacturers of industrial and commercial racking and shelving for warehousing and storage solutions.

For more information and a full catalogue of our products please visit us at www.universal-storage.co.za

Mobility for the SME S mall to Medium sized Enterprises (SMEs) are a fast-growing sector of the local economy, but face a multitude of challenges including remaining competitive, particularly with their larger counterparts. These challenges include limited resources, limited budgets, the fact that they have to ‘multi-task’ and still somewhere in between focus on their core business. This has forced smaller companies to become more agile. Working ‘on the go’ is one way for these smaller businesses to increase productivity and ‘juggle many balls’ so to speak. This is according to Dawie Bloomberg (pictured), MD, Green Apple IT However, one of the major barriers to mobility is that the ICT infrastructure of a small business simply cannot accommodate a mobile HTPE Advert October 2013.pdf 1 2013/10/21 workforce. Fortunately, cloud applications and

services, such as Microsoft Office 365, have become increasingly available, affordable and practical. These cloud services and applications underpin and support mobility, enabling SMEs to become the agile enterprises they need to be, and take advantage of technology that was previously only available to large corporates. Adopting cloud offerings has proved to be somewhat taxing for SMEs in the past, which has limited their ability to effectively work from multiple locations. For example, many SME organisations may have a server at their premises, which stores documents and information. To enable mobile working, the service and notebook or laptop must be set up for remote access, which is only possible when the server is switched on. Accessing documents and files 3:12 PM at night or when the office is closed therefore becomes challenging, unless the server is left on at all times, which poses a risk in case of power fail-

M C

Hi-Tech Pressure Engineering is a medium sized engineering company based in South Africa. Hi-Tech designs and manufactures pressure vvessels and pressure parts in accordance with international engineering standards. We make compliant pressure equipment for all industries that require compliance to pressure vessel regulations.

February / March 2014

company & product News

CMY

• Pressure vessels

• Stainless process vessels

• Pressure systems

• Heat exchangers

• Storage tanks

• Air receivers

• Level control vessels

• Boiler equipment • Seal vessels

8 Sage Road, Jacobs. P.O. Box 41349, Rossburgh. Tel: (031) 461 4193 • Fax: (031) 461 4194 info@htpe.co.za • www.pressure.co.za

KZN Industrial & Business News

ure, and also increases energy consumption. Power outages can also pose a challenge during office hours, as users may have notebooks that will operate on battery power, but will have limited time to access the server even with a UPS, which can hamper productivity. One solution is to use offline folders on users’ notebooks, which enables them to access a cached version of documents. However, this information must then be synchronised back to the server, and if other users have been working on the same documents in the interim, conflicted versions of these documents occur, and updates may not include all changes. Collaboration therefore becomes impractical. Traditional office-based servers can also be a capital-intensive exercise, as the SME is required to purchase the infrastructure to not only store data and applications, but also access these. There is however a solution that addresses all of these challenges and provides the mobil-

ity, access and collaboration tools needed by smaller businesses to become more agile and competitive. The emergence of cloud-based applications such as Microsoft Office 365 have changed the game for SMEs, providing access to critical information whilst on the move and improving productivity. Office 365 provides SMEs with access to the full suite of Microsoft Office tools from virtually anywhere, on multiple devices including PC, Mac and mobile devices, as well as access to business-class IT services that are easy for the SME to administer. It also offers enterprisegrade email with Exchange, which allows for larger documents to be emailed and provides email archiving for compliance purposes, along with offsite email storage and archiving for improved failover and redundancy. Shared calendars can be accessed by staff members at their desks and on the go for improved timekeeping and organisation. Office Web Apps allow users to create, store, edit and share Office documents online for maximum availability, while file sharing allows for collaboration, and included video conferencing. SharePoint Team Sites are also available when company-wide documents need to be managed.

Enquiry no: 104

Control van sales with new Drop’nBank Solution

any smaller shops and consumer outlets like spaza shops and shebeens are dependent on quick responses from their suppliers to replenish stocks as an alternative to them visiting the wholesaler or Cash and Carry. For distributors to meet these needs, they must have vehicles stocked with a selection of goods that call on these outlets regularly as well as manage the risk of cash collection. Due to the nature of these smaller outlets, many of the transactions are cash based, requiring drivers to collect payment and issue invoices and receipts, leaving administrators at the distribution point with the task of cash and stock settlement later. To simplify the process of selling products from vans and other vehicles, Mac Web Pty Ltd has developed a solution combining mobile devices and a hosted cloud application to give distributors and their driver’s better control over the products, cash collected and cashless banking on a real time basis. Using the MACmobile Drop’nBank Van Sales Solution, stock loaded onto a vehicle is recorded on a Web-based management system. The stock list

is then downloaded onto the Driver/ Salesman’s mobile device, along with the route he is to take that day. Once the driver has checked that the stock in the van matches the list on his device, a stock list is printed from the mobile via a Bluetooth printer and signed by the driver as acknowledgement of receipt of the load. “Before leaving in the morning, the driver records the starting mileage of the vehicle, and then follows the route planned for him,” explains Andrew Birch, Mac Web Pty Ltd, Managing Director. “At each drop the driver logs in to confirm that he is at the specified location. The system automatically records the time and GPS coordinates, and requests mandatory

submission of the mileage reading.” All transactions are then recorded on the mobile device , and a priced invoice receipt is printed on the incab Bluetooth printer for the shop owner and driver to sign. The amount of money collected or the cashless payment amount is also recorded to provide the real–time reconciliation of cash, cashless payments, stock issues and stock on hand. On completion, the driver closes the outlet’s account on the device and moves to the next drop destination. If any delivery is unable to be made for any reason, this is noted via a dropdown reason code . In an emergency, the driver can receive the instruction on the device to deviate from his route and add in an “Emergency Call”, noting the time and other required details, as well as the reason for the emergency deviation. After each stop, all data is uploaded to Mac Web’s servers to ensure real time information on every driver. If the vehicle is in an area with no cellular coverage, the driver can work offline until he enters a coverage area when the system will synchronise automatiEnquiry no: 105 cally.

Retail logistics for pharmaceutial company

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three year contract for warehousing and distribution services has been awarded to Imperial Retail Logistics by Colgate-Palmolive. The Imperial Logistics group is undertaking the national warehousing, primary and secondary distribution of Colgate-Palmolive’s entire range, including the Protex and Sanex brands, reveals operations director Friedel Spies. An average total of 290 primary loads will be transported on a monthly basis. In addition, the outsource contract will see Imperial managing Colgate-Palmolive’s warehousing on an national basis, as well as offering dedicated customer service and various support functions - through its extensive IT resource network. “We will leverage our specialist knowledge, processes and technology to offer a complete, customised warehousing and secondary transportation solution aimed at boosting Colgate-Palmolive’s competitiveness,” Spies Enquiry no: 106 adds.

February / March 2014

company & product News

KZN Industrial & Business News

Global leader grows SA footprint

ilfisk-Advance A/S, a global leader in the production of professional cleaning equipment with a track record spanning over 106 years, has further strengthened its presence in Southern Africa through the acquisition of Industroclean (Pty) Ltd. Consequently, Industroclean has become a wholly owned subsidiary of Nilfisk-Advance A/S with effect from January 2, 2014, joining the Danish based Nilfisk-Advance Group’s world spanning network of 45 sales companies. Nilfisk Advance also operate production plants on 4 continents, in 8 different locations and points to sales / service distributor representation in a further 100 countries, around the world. Founded in 1980, Industroclean has established itself as a leading supplier of cleaning

equipment and floor care chemical products with a country-wide branch and distributor infrastructure. Industroclean bring considerable technical expertise and problem solving capabilities to the relationship. A strong focus on product quality, reliability and customer care, has made Industroclean a preferred supplier to a wide range of customers, throughout the contract cleaning, retail and facilities management sectors, as well as private and public health care institutions. The acquisition of Industroclean brings Nilfisk-Advance’s number of sales companies in Southern Africa to two, bearing in mind WAP South Africa (Pty) Ltd was successfully integrated into the Group, in 2007. In a new strategic partnership, the two Nilfisk-Advance A/S owned sales company’s combined market presence will bring an industry leading, integrated suite of cleaning solutions to customers around Southern Africa. Although WAP South Africa and Industroclean share some similarities when it comes to size, background and infrastructure, the two companies have traditionally concentrated on different market segments. WAP South Africa being active in the automotive, engineering, manufacturing, mining, food and beverage, as well as agricultural sectors, whereas Industroclean has focused essentially on the contract cleaning, retail, health and institutionalised segments.

he local commercial vehicle market had a somewhat slower start to the year, selling 5.39% less trucks during January compared to the same month in 2013. 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), a total of 1 861 trucks were sold during January. “A slight slump in sales was expected as the domestic truck market ended 2013 on such strong footing,” said Jacques Carelse, managing director of UD Trucks Southern Africa. “As the year unfolds, we are expecting to see that the strained local economy, as well as the volatile Rand and continuing labour and social unrest, will contribute to a lower growth rate in the industry.” Looking at the various segment’s performances during January, Medium Commercial Vehicles declined by 1.41% year-on-year to conclude the month on 769 units. Sales in the Heavy Commercial Vehicle segment declined by 19.45% to 265 units, while sales in the

Enquiry no: 107

Evolving repair and maintenance model achieves management aims equipment in service at a specific operation. Sales activities, training, repair work and maintenance contracts are executed out of these centres and each carries a certain amount of stock to support the particular requirements of its local customers, making these services as cost-effective as possible. The most recent Multotec service centre to be established is located in Mokapane, Limpopo Province, effectively expanding the company’s services in the Eastern Limb/ Steelpoort area. The new centre has a fullyfledged administration and sales office, workEnquiry no: 108 shop and storage area.

All field service personnel are technically trained and certified through Multotec’s comprehensive training centre in Spartan.

ith the mining industry’s intensifying focus on managing the lifecycle cost of its equipment, the nature of the repair and maintenance model has evolved well beyond process equipment companies going onto site to change out a component and then pulling back. Today these suppliers have become an integral part of the decisionmaking process driving an operation’s maintenance discipline. “Our whole maintenance philosophy has changed, together with the scope of our product offering,” Garth Jones, general manager services at Multotec, says. “The nature of the business has moved on from being purely a repair and maintenance service to working closely with the customer to achieve management aims for the operation.” “A lot of innovation is driven through this close relationship, in which the customer’s long term objectives are the common goal. Opportunities for process improvement on a customer site frequently become apparent and new product trials can be conducted in a very controlled, authentic mining environment. Where these trials lead to innovation, we’re often able to pass on best practice to other customers to help improve their own processes.” Jones adds that in order to sustain this close association with its customers, Multotec has established an extensive network of service centres in close proximity to customer operations, assuring rapid reaction times and a 24 hour presence for the products that require this level of support. In several cases, service centres have actually been established on customer sites, where personnel are dedicated solely to supporting the Multotec

A reliable floor maintenance crew. The B40, fast and easy to use with an intuitive menu-based user interface operating system. Perfect for the maintenance of most floor types. It makes business sense. 33 Henry Pennington Road (Richmond Road), Westmead Tel: (031) 713 4700 or email: garin@karcher.co.za www.karcher.co.za

Slow start for truck sales Extra Heavy Commercial Vehicle segment showed a 6.11% decline to 769 units. Only Bus sales offered some hope, with a 48.72% increase in sales to 58 units, due to the delivery of some Bus Rapid Transit units. The lower Rand exchange rate, does however, bode well for vehicle exports, especially into other African countries. On the other hand, it also means an inevitable hike in truck prices during the next six months. The recent dramatic increase in the diesel price is also sure to hit the economy and especially transport operators and ultimately consumers quite hard. “On the positive side, we believe the Gross Fixed Capital Formation or GFCF, the new value that is added to the economy, is set to increase slightly during 2014 with the main gains coming from several construction and infrastructural projects. For this reason, although many industry analysts are forecasting a very stagnant local market, we are remaining positive that the market will see growth of around 4% this year,” concluded Carelse. Enquiry no: 109

February / March 2014

KZN Industrial & Business News

etso’s latest generation Lokotrack ST2.4 mobile screen combines high capacity performance with fuel efficient operation to provide the lowest cost per tonne in its class, thanks in part to the optimised hydraulic design and state-of-the-art process steering automatics. The Lokotrack ST2.4 processes a diverse range of feed materials, from the pre-screening of the coarsest gravel to fine classifying and processing of natural sands, or any demanding recycle materials. Three clean end product sizes can be produced in one process due to the ST2.4’s two-stage screen set-up. A variety of screen media can be fitted, from steel meshes to rubber and polyurethane materials. All the conveyors are folded hydraulically and secured mechanically. “You just set up the screen angle, lift the feeder up and start screening,” says Kimmo Anttila, product manager for Metso mobile screens. (Barloworld Equipment is Metso Mobile’s southern African distributor.) The Lokotrack ST2.4’s screen box size measures 3,6m in length with a width of 1,5m. Machine and track systems are powered by a

Desktop provides a larger surface and integrates an angled clipboard designed for postural relief.

Work Assist™ post used to mount a data terminal or scan gun.

Extra wide compartment facilitates entry/exit and provides superior postural relief with generous amounts of knee and leg room.

MoveSeat™ rotates 30 degrees for reduced upper body twisting.

Adjustable armrest features integrated controls that move with the seat. Shown with multi-task hydraulic control.

FlexBack™ with quick-adjust lumbar support reclines for improved upward visibility and reduced back strain.

Integrated headrest provides postural support and reduces neck stress.

High capacity, multi-product screening

ower, performance, durability, ergonomics, maintenance and serviceability provide across-the-board 2 superiority throughout the completely re-engineered, new generation compact M-series. The product range includes the S510, S530, S550, S570, S590 and T590. The superior design, heavy duty construction, component protection and rugged reliability of the new M-series will run up production and run down total cost of ownership on any site. The re-engineered hydraulics system which consists of a higher standard flow, combined with lower backpressure and high hydraulic pressure, results in 20% improved hydraulic efficiency. Improved attachment performance increases overall functionality by working faster and more efficiently. The increased tractive effort enables operators to push more and dig harder than ever before. Stronger hydraulics and better tractive effort also results in faster cycle times. “With operator safety and comfort always taking precedence, cab space has been increased by 10%, giving more room all around. The cab is not only bigger but quieter with a 60% noise

Energy Efficiency5 Explained 6

More Run Time Per Charge

Visibility • Visibility that Drives Success Multi-task hydraulic control

Dual-lever •Fingertip Stability that Builds Confidence controls

tation, the 25 ton Lokotrack ST2.4 is 14,2m long, with a height and width of 3,4 m and 2,9 m, respectively, enabling rapid deployment between sites, which is the primary objective of mobile crushing and screening operations. Enquiry no: 110

More, better, faster performance

Only Crown offers an offset mast for unequalled visibility to the load wheel and forks. The clear-view mast design and patented overhead guard minimise obstructed views during driving and lifting operations.

74.9 kW Cat C4.4 diesel engine. Optional features on the ST2.4 include a vibrating apron feeder with grizzlies or finger bars, a lamer feeder, a magnetic separator for recycling, and remote radio controls. Designed for on-road transpor-

controls

• Performance that Rises Above

Control options for the ESR 5200 Series include the choice of multi-task (ESR 5260 and 5280S only), ﬁngertip, or dual-lever hydraulic • Longevity thatcontrols. Pays Other control-enhancing options include an adjustable steering column and armrest.

More Pallets Per Hour It just makes sense... Branches in: Johannesburg (Head office), Durban, Cape Town & Port Elizabeth Tel: 010 594 4339 • lifttrucks@goscor.co.za www.goscorlifttrucks.co.za A proud member of the Goscor Group of Companies

reduction which improves the working environment, jobsite communications and subsequently leads to better production. Noise and vibration are further isolated by the new engine mounts.” Reports Michael Burns, National Sales and Marketing Manager at Bobcat Equipment South Africa (Pty) Ltd. The intelligent full-colour deluxe instrumentation panel with optional keyless start as well as monitoring and interactive functions further improve operation. Operation levels are clearly displayed on the new 7” (18cm) full-colour LED screen with easy-to-read virtual sweep gauges. Important controls like engine speed control and operator switches are located right in front of the operator. The 14% larger window also increases visibility. The new cab-forward moves the operator area closer to the attachment, giving a better vantage point of the work area. Bobcat loaders with enclosed cabs are air-conditioned and have a best-in-class, pressurised interior space that helps keep dust to a minimum. Increased light output of over 50% provides a brighter environment. The cooling system has been re-engineered for improved performance and extended machine life while increased fuel capacity extends operation time. Enquiry no: 111

February / March 2014

KZN Industrial & Business News

Registration for paint courses

egistration is now open for training offered by the SA Paint Industry Training Institute (SAPITI), the training arm of the SA Paint Manufacturing Association (SAPMA). The courses will all be presented at SAPMA new training facility, The Coatings Industry Centre of Excellence, in Springs but in-house training options as well as formalised training in selected Cape Town, Durban and Port Elizabeth venues will also be available for some of the courses. During the first half of the year SAPITI will offer training in: • Paint Technology Qualification; • Raw Material Preparation Skills Programme (CHIETA Accredited NQF 2 level); • Decorative Retail Theory Programme; and • Applicator Skills Programme. In the field of technical training, SAPITI will offer Surface Coatings Technology Part 1 – for staff working in a QC lab, technical sales reps and raw material supplier reps. This course includes subjects such as Basic Technology, Application and Evaluation.

Also on offer will be Surface Coatings Technology Part 2 for staff whose careers are focused on product development or formulation, technical support, trouble shooting and problem solving. Here the curriculum includes Surface coatings Technology Part 1, Pigments, Modifiers, Solvents and binders, Convertible binders, and Formulating principles, formulation including project management. The Paint Technology Qualification course offers industry-specific training modules and technical qualification for staff following a technical and sales career (sales reps NQF 4 to 6). The course started in Johannesburg and Durban in February and will be offered

in Cape Town and Port Elizabeth in May. It includes 11 elective modules. Raw Material Preparation Skills (CHIETA NQF 2) is ideal for plant operators, assessor trainees, supervisor trainees, labelling and packaging staff, and raw material warehouse staff, among others. Contact SAPMA for dates of this training for this fiveday course starting in Johannesburg from March 4 which can also be presented in-house. The Decorative Retail Programme (NQF 2) started in Johannesburg at the beginning of this year and the five-day course could also be offered in other cities depending on demand. It is ideal for sales and DIY personnel, owners and supervisors of applicator firms, and non-technical staff wanting to learn more about preparation of surfaces and application of paint. In-house training is also available for Applicator Skills Programme (NQF 2). This course offers theoretical and practical training sessions followed by workplace training. The SAPITI training programme for the second half of the year will be announced later. For further information email trainEnquiry no: 112 ing@sapma.org.za

South Africa internship programme

ipro Ltd, a leading global Information Technology, Consulting and Outsourcing company, has announced plans to expand the intake of graduates for its successful internship programme in South Africa. Now in its second year, Wipro’s local internship programme in South Africa enrolled 70 graduates in 2013 and this will be increased to 150 in 2014. “The internship programme is becoming a crucial enabler of Wipro’s growth in Africa. “For us, the programme is about nurturing talent for local leadership and ensuring that we have the right people on board – people who understand local culture, local markets and local customers across the African continent. “We look for people that fit the entrepreneurial spirit of Wipro – those who have a willingness to learn and a creative and innovative mind,” said Saurabh Govil, Senior Vice President, Human Resources, Wipro Ltd. Internship applicants (B.SC students with a specialisation

in Mathematics and Science) from disadvantaged backgrounds are put through a process of entrance exams and interviews with local Wipro leadership to test attitudes to learning in addition to technical aptitude. Post completion of the initial three months of theoretical training the interns are interviewed for an apprentice role on a number of live projects. Once placed, the interns will receive supervised, on-the-job training and mentorship for a further three months.

The performance records will be reviewed and qualifying interns will be absorbed into Wipro’s operations in South Africa. Govil added, “The programme gives the interns a chance to work on ‘live’ client projects, to gain in-depth experience in everything from software development and project management, to client relationships, and crisis management. The programme offers a very high chance of being absorbed into the company - the first batch of 30 interns from 2013 is now employed full-time at Wipro. This program literally opens up a world of opportunities to work on projects wherever Wipro operates.” Interns are assigned mentors, and receive weekly feedback and undergo periodic assessments on their performance. The overall curriculum has been designed to bridge the gap between campuses and the industry, and covers both technical and behavioural aspects. Enquiry no: 113

TALK TO YOUR TARGET MARKET Upcoming features in April / May 2014 • • • • • • •

Automation & Robotics ICT in Industry Machine Tools Metals, Alloys & Fabrication Petrochemicals Transport, Distribution & Warehousing Water & Effluent Management For all editorial contributions contact Chantal Haines For advertising Cheryl Murphy Tel: 031 266 7511 Email: editorial@mediaevents.co.za

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www.sandvik.coromant.com/productnews 64 Jet Park Road, Jet Park • PO Box 25038, East Rand, 1462 • Branches: Durban, Port Elizabeth, Cape Town, Vaal Triangle • Direct Sales: 0860 101 008 Fax: 0860 101 006

February / March 2014

SCENE AROUND

Seen at the African Frontiers Forum are from left, Andy Robertshaw, Arup consulting Engineers with Stefan Coetzee, Micheal Turner and Gareth Bowman, all Turner and Townsend

KZN Industrial & Business News

Seen at the launch of the 2014 Sanlam / Business Partners Entrepreneur of the Year competition, are from left, Vani Moodley, Vani Moodley & Associates, Charmaine Schwenn, Tate Nolan & Knight Attorneys and Aneska Dupont, Aneska Dupont and Associates

Also at the competition launch are from left, Arthur Charles van Wyk of Fluence and Ryan Jones of Three Peaks Management

Remote areas pose a challenge to logistics

T New national sales director

for truck company

ark Gavin has been appointed National Sales Director for DAF’s southern African operations. Gavin has been in the truck business since 1994, gaining a depth of experience in all operational aspects of the local industry during his tenure at other European truck distributors during this time. “I have a tremendous passion for European trucks and I regard DAF as a word class brand,” says Gavin. “It’s the market leader in the UK and is among the top three in Western Europe. Although DAF presently has a small market share in Africa, I intend to challenge this – there’s absolutely no reason why these trucks cannot compete with the brands that occupy the upper levels of the local market. “ “DAF trucks are well suited to African conditions and, coupled with European efficiency, safety, comfort and reliability, the local market receives the best of both worlds. Worldwide DAF is synonymous with these advantages and the African market is now beginning to recognise this. DAF offers one of the lowest vehicle tare weights in South Africa, as well as low fuel consumption and comprehensive warranties. We’re also geared to meet the growing demand for Euro 5 emission standards, with products that can

run on locally available diesel. All these factors make DAF an excellent choice in terms of Total Cost of Ownership.” “Babcock will continue to back the DAF brand in the long term. We’re here to stay as a player in the African trucking industry and my immediate focus will be on ensuring that new and existing customers are offered the right products at the right price for the applications in which they operate, and that they receive a consistently first class aftersales service. The building blocks are already in place and I plan to consolidate these strengths to grow our market share. DAF head office, based in Benoni on Johannesburg’s East Rand, houses the Parts Distribution Centre (PDC) that services the Babcock and independent dealer network throughout southern Africa, ensuring parts availability, as well as a technical and driver training centre to ensure all dealers technical and commercial staff are adequately trained to offer the correct service and advice to customers. Other Babcock dealerships are based in Middelburg, Cape Town and Durban, while Babcock’s DAF network offers everything from a routine service to a tailor-made repair and maintenance contract, together with full aftersales support. Enquiry no: 114

he movement of goods and people to and from remote regions has always been a challenging process, due to varied factors such as geographical obstructions, long distances, natural weather anomalies and even socio-political instability. perators of remote projects rely on environmental, communication and transport infrastructure that fosters expenditure reduction and efficient delivery, partnering with reliable logistics providers. According to Detlev Duve, Managing Director of Dachser Logistics South Africa, technological advancements and heavy investments into transport infrastructure across the continent have enabled logistics providers to take advantage of expansion into remote areas. Improvements in the port areas, such as the Durban Harbour project, aviation port

of entry and road infrastructure improvement contribute to making the movement of goods fast, efficient and cost effective. “The construction and mining industries are the most in need of logistics solutions as they frequently have sites in remote and inaccessible areas,” says Duve. “We’re finding that a high level of activity is continuing across remote locations. Many project managers face real challenges in a logistical sense, challenges which we can address through our specific experience in the African environment.” To date, Dachser has undertaken remote projects in the KwaZulu-Natal and Eastern Cape regions. According to Duve, effective logistics planning for remote locations contributes directly to the success of these projects being cost-effective and completed on schedule. “We are always looking for innovative

ways to move our customers’ goods. “Special considerations must be made when delivering goods to remote locations. We look at the distance, road infrastructure, carrier efficiency, fuel consumption and security,” says Duve. “To ensure successful operations, it is important for us to have the right equipment and strategy to ensure that we can meet the delivery deadline, given the obstacles we may encounter in these remote locations. It is very crucial to select the best carrier to use for remote projects, a carrier that can manage poor roads and long distances.” Duve further explains that in order to improve logistics in remote locations, companies need to invest in adding smaller distribution centres in areas where sufficient cargo justifies the investment. Enquiry no: 115

Wired for waste Wastecon 2014

frica’s largest waste management conference, WasteCon, hosted by the Institute of Waste Management of Southern Africa (IWMSA) will be taking place from 06 - 10 October 2014 at The Lord Charles in Somerset West. “This year it is the turn of the Western Cape Branch of the IWMSA, to host WasteCon2014. With the theme ‘Wired for Waste: value * grow * sustain’ and promises ‘action, action and more action”, according to Dr Suzan Oelofse, President of the IWMSA. With a multitude of national and international specialists sharing their insights and experience, and showcasing advances in the industry, the multi-day conference is geared to providing real solutions and inspiration for change. Speaking on the theme, Oelofse says that value, growth and sustainability will underpin every event at the conference. “How we value waste as a resource ultimately determines how much time and money we are prepared to invest in its management,” says Oelofse. “We need to realise a shift in focus from the conventional approaches to value-add strategies and affordable management options.” “To ensure progress we need to change as our environment changes,”

adds Oelofse. “Through transforming and integrating value-add initiatives, we need to actively engage opportunities that promote growth – these may be entrepreneurial opportunities, job creation, promotion and support of SMME’s and green energy initiatives.” Entrepreneurs are invited to use the opportunities presented at WasteCon2014 to showcase their skills and expertise and in so doing, become a vital part of the much-needed change. According to Melani Traut, IWMSA Western Cape Branch Chairperson, sustainability does not only refer to the limitations of our ecosystem, but rather

to the economic and social sustainability for which we as human beings are responsible. “To live within the limitations of the biophysical environment, we need to embrace the three types of capital (natural, social and human) to ensure a shift in focus, ensuring growth that is achievable without compromising our future potential.” The exhibition component of the conference gives all industry-related companies and organisations a fantastic opportunity to promote their services, products and ideas. Interested parties can book space or find out more at www.wastecon. Enquiry no: 116 co.za/exhibition.html.

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