Sa Plastics, Composites & Rubber

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As the demand for more stringent flammability and thermal requirements in plastic parts increase, so do the demands on the raw material used. Subsequently, raw material manufacturers are continuously developing and improving materials to meet these demands like introducing Halogen and Bromine free flame retardant materials. See editorial on pages 78-80. For more info call 0800 006772 or visit www.plastichem.co.za

Carry on where others leave off. The VEGA range.

No more compromises! For effective materials processing you need perfectly functioning technologies, regardless of whether you want to process plastics, paper, rubber or other materials. With the Vega shredder range you have a solution with a proven concept right down to the last detail and individually customised to your requirements. UĂŠ -ĂŒ>ĂŒi‡œvÂ‡ĂŒÂ…i‡>Ă€ĂŒĂŠÂ“>V…ˆ˜iÀÞ UĂŠĂŠ*>ĂŒÂ…ĂŠvÂœĂ€}ˆ˜}ĂŠĂŒiV…˜œÂ?Âœ}ˆiĂƒĂŠĂƒiĂŒĂŠÂ˜iĂœĂŠĂƒĂŒ>˜`>Ă€`Ăƒ

Ingenious to the last detail UĂŠ *ÂœÂˆÂ˜ĂŒÂ‡LÂ?>`iĂŠ Ă€ÂœĂŒÂœĂ€\ĂŠ ÂŤĂ€iVÂˆĂƒiĂŠ VĂ•ĂŒĂŒÂˆÂ˜}ĂŠ iÂ˜ĂƒĂ•Ă€iĂƒĂŠ …ˆ}…‡ through put and long life shredding of difďŹ cult materials UĂŠĂŠ*>ĂŒiÂ˜ĂŒi` UĂŠĂŠ œ˜œwĂ?ĂŠĂƒĂžĂƒĂŒi“ÊvÂœĂ€ĂŠv>ĂƒĂŒĂŠLÂ?>`iĂŠĂ€iÂŤÂ?>Vi“iÂ˜ĂŒ° ĂŠUĂŠĂŠ-¾Õ>Ă€i‡LÂ?>`iĂŠĂ€ÂœĂŒÂœĂ€\ʓ>Ă?ÂˆÂ“Ă•Â“ĂŠÂŤÂœĂœiĂ€ĂŠĂœÂˆĂŒÂ…ĂŠÂ“ÂˆÂ˜ÂˆÂ“Ă•Â“ĂŠĂŠ drive power and low rotational speed. UĂŠĂŠ/Â…iĂŠĂƒVĂ€iiÂ˜ĂŠVÂœÂ˜ĂƒĂŒĂ€Ă•VĂŒÂˆÂœÂ˜\ĂŠv>ĂƒĂŒiÀÊ>VViĂƒĂƒ° UĂŠ "ÂŤiĂ€>ĂŒÂˆÂœÂ˜ĂŠ >˜`ĂŠ Ăƒ>viĂŒĂž\ĂŠ VÂœÂ“ÂŤÂ?iĂŒiĂŠ VÂœÂ˜ĂŒĂ€ÂœÂ?ĂŠ iÂ˜ĂƒĂ•Ă€iĂƒ ĂŠĂŠ “>Ă?ÂˆÂ“Ă•Â“ĂŠĂƒ>viĂŒĂžĂŠ>˜`ĂŠÂœÂŤĂŒÂˆÂ“>Â?ĂŠÂœÂŤiĂ€>ĂŒÂˆÂœÂ˜ĂŠVÂœÂ˜Ă›i˜ˆi˜Vi°

Shredding technology to the ďŹ nish.

RELLOY S.A.

(Pty) Ltd

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BY THE WAY ...

New era dawns with

Publisher: Martin Wells (martin@summitpub.co.za) Editor: Tessa O’Hara (tessa@summitpub.co.za) Editorial assistant: Heather Peplow (heather@summitpub.co.za) Financial manager: Lisa Mulligan (lisa@summitpub.co.za) Designer: Bronwen Moys (Blinc Design)

Summit Publishing cc t: +27 (21) 712 1408 f: 086 519 6089 c: +27 (82) 822 8115 e: saplastics@iafrica.com Postnet Suite 42, Private Bag X16, Constantia 7848, Cape Town, South Africa 70 Newton Drive, Meadowridge, Cape Town

www.saplastics.co.za

GAUTENG Lowrie Sharp t: (011) 793 4691 f: (011) 791 0544 c: 082 344 7870 e: lowrieplasticsmedia@absamail.co.za KZN Lynne Askew t: (031) 764 2494 f: (031) 764 0676 e: lynne@leafpublishing.co.za Europe & UK Eddie Kania RGH International, High Peak, England t: +0944 1663 750 242 e: ekania@btopenworld.com Printed by: Tandym Print, Maitland, Cape Town SA Plastics Composites + Rubber Technology is published six times a year and focuses on these industries in South and southern Africa. We welcome news, articles, technical reports, information in general and photographs about events and developments related to the plastics industry. The views expressed in the magazine are not necessarily those of the publisher. Views expressed are not necessarily those of the Plastics Converters Association, Institute of Materials or Association of Rotational Moulders either. Copyright: All rights reserved. ISSN number: 1684-2855 (ISDS Centre, Paris) Summit Publishing: CK 9863581/23 VAT reg: 4600187902

Association of Rotational Plastics Institute

Moulders of South Africa

of Southern Africa

Plastics Converters Association

PET Plastic Recycling

Plastics Federation

South Africa

of SA

Institute of Materials

POLYCO A NEW ERA dawns for the industry in April when POLYCO, the Polyolefins Company, starts out on its journey. Although it constitutes by far the largest percentage of material converted, the polyolefins sector has been the last to mobilize. PETCO, for the PET sector, was the first of the material sector associations to be established in 2005. It’s been followed by the Polystyrene Packaging Council (PSPC) and SA Vinyls Association (SAVA) for the PVC sector. These bodies are funded by either a levy on material sales or other mechanisms. It’s possible that the establishment of POLYCO was delayed simply because of the magnitude of the undertaking. The polyethyelene and polypropylene converting business is diverse and widespread. It accounts for more than half the total tonnage of material converted in South Africa annually, estimated at between 600,000 and 700,000 tons p/a. What is of immediate importance to converters is that POLYCO will be funded by a levy of R100 per ton of material purchased. The levy, which will at first be voluntary, comes into effect on 1 April. We understand that the major converting groups have in principal agreed to participate, so the accrued fund should growing within the first few months. Should everyone pay, a substantial fund will obviously be established. POLYCO will focus on improving waste Benefits of management and recycling of post-consumer membership polyolefin products in terms of the industry’s Extended Producer Responsibility (EPR) comwill surely be the mitment, and hopefully pave the way for an main catalyst environmentally sustainable future. for joining Self-regulation is certainly preferable to state intervention, an aspect that the bag-making sector remains very aware of. The plastic bag legislation of 2002 led to a complete overhaul of the bag business, and worse was to come: virtually none of the capital generated from the plastic bag levy came back to the industry. The entity set up to run the process, Buyisa-e-Bag, has been shut and consumers are still paying the bag levy into the government coffers. So the whole process has effectively not assisted the industry at all. But memory of the experience may be useful: POLYCO will after all be managed by representatives of the polyolefin industry, and they should be mindful to avoid the previous disaster! One suitable initial goal may be to retrieve the lost millions and possibly access the funds from the bag levy going forward? PETCO encountered difficulty with some PET converters in its early stages, but organisation and action slowly won businesses over and the PET levy is at present being paid by virtually the entire sector. Businessmen around the country will be watching the process with interest and caution, and we suspect many will adopt a wait and see approach. R100 a ton will on average be about a 1-2% of their overall material costs, but adding a single percent onto total production costs will not be taken lightly, such is the competitive nature of the market presently. It’s also not certain that the industry’s customers will be enthusiastic about a 1% increase in prices. Experience suggests they won’t, and the fact of the matter is that non-payers of the levy will, in theory at least, immediately achieve a 1% cost advantage over levy payers. This has indeed happened before. We, however, suspect that the better organised businesses will pay the levy and, almost invariably, such well managed operations tend to succeed before others. Observation of the benefits of membership will surely be the main catalyst for joining, so the next few months and years will be very important for the new organisation. It needs to build confidence and realize improvements for the industry in terms of building market share, improving our environmental image, standards, training and – in short HAVE – everything that a healthy industry involves. … IF YOU Y NG TO SA : if you We hope POLYCO gets off to a flying start! SOMETHI si bright de

e Look at th wisdom to e gem of at have som rite to us w se ea impart, pl frica.com ia s@ tic saplas

REGLOPLAS High-performance temperature control units Find out more at www.saplastics.co.za

Volume 10 Issue 2

APRIL – MAY 2012

Contents 12

NewLife Plastics develops ‘mitigation’ concept

14

10

ASSOCIATION NEWS SAPPMA, DPI help keep oceans tangle-free

32

PETCO: Eco organisations create value

36

PISA: Fire in focus

40

PEOPLE Hestico major sponsor of cycling club

50

Triple8’s Martin oors it in restored ’61 DKW

52

74

Bringing design & industry together

94

Type 150 Smart

UĂŠ ÂœÂ˜ĂŒĂ€ÂœÂ?Â?iÀÊ,/ĂˆÂŁĂŠ*

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16

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70

WORLD 105

s 3IMULTANEOUS READOUT OF TEMPERATURE set-point and actual value s #LEAR ARRANGEMENT OF OPERATING AND indicating elements

DIARY

s 3OLID STATE RELAY 332 INSTEAD OF heating contactor

107

SPORTS Solvay marks 25yrs of PARA resins

UĂŠ ÂœÂ˜ĂŒĂ€ÂœÂ?Â?iÀÊ,/ĂˆÂŁĂŠ*

Temperature control units for oil up to 150°C

DESIGN Innovations to transform the future

Events coming up in 2012

Temperature control units for water up to 90°C

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6

Hestico celebrates 50yrs

Plastic egg for world’s biggest egg hunt

Type 90 Smart

UĂŠ i>ĂŒÂˆÂ˜}ĂŠV>ÂŤ>VÂˆĂŒĂžĂŠÂ™ĂŠÂŽ7

INDUSTRY NEWS PlantBottle™ at outstanding ‘greenďŹ eld’ project

‌ for large injection moulds, extruders, rollers, autoclaves and other processing equipment

112

89

s !LL COMPONENTS EXPOSED TO WATER ARE made of non-rusting materials, hence long service-life s !CHIEVES ESTIMATED REDUCTION IN REJECTS AND INCREASE IN PRODUCTIVITY

ON THE COVER CORAL Chem in conjunction with its principal, Geotech International BV, will host a training seminar in Cape Town, Durban and Johannesburg during May covering colour effect pigments (glitters, pearlescents, glass and aluminium pigments). (COVER PHOTO BY GEOTECH INTERNATIONAL BV)

See page 96 for more information

JENOWILL SERVICES #ONTACT n 7ILLY 4SCHOPP 4EL &AX # ,ILLY 0ARK 2AILWAY 2D -ONTAGUE 'ARDENS #APE 4OWN JENOWILL IAFRICA COM WWW REGLOPLAS COM

THIS ISSUE The Valpré mineral water bottling plant at Heidelberg was constructed to the highest specs

Martin Wells

, Publisher

THE ULTIMATE PLANT!

COMMENT

F

INALLY we have it, the ultimate plant!

Well, if it’s not, it must be very close to it. Coca-Cola group’s new Valpré mineral water bottling plant at Heidelberg in Gauteng has just about everything: all operations are literally conducted within the attractively designed building set on the rolling highveld hills. All input materials enter at one end and loaded trucks emerge from the other. The plant is being used to produce Valpré’s still and sparkling mineral water range. Its relatively remote location at Heidelberg is due to the need for mineral water to be bottled on site. Designing the ultimate plant is something that many in the industry have dreamt of, and some have even overseen with success. It takes years of experience, planning, teamwork, courage … you name it! Here the planners at Coke have gone off the scale. Virtually no expense has been spared: solar panels hum quietly in the landscaped gardens, supplying power for the nonmechanical needs, diesel generators produce enough current to run a plant twice the size. Even the road to the plant was upgraded for allow for easier trucking. We were too scared to ask about the full cost, but it must run into hundreds of millions. The development is part of Coca-Cola’s global PlantBottle™ programme for the use of naturally sourced materials. It’s the tenth PlantBottle plant to be commissioned by Coca Cola internationally and is a major undertaking by the global softdrink group in South Africa. Read about it on pages 6-8. Eco organisations can create value PETCO, one of the role models for the other ‘new’ professional associations which have emerged over the last few years, held an unusual event recently: it invited other eco organisations to address workshops it hosted in Johannesburg and Cape Town. For many

36 4

APRIL / MAY 2012

16

105

in the manufacturing sector, attending to the ‘green’ lobby has been a bit of a nuisance, something which interfered with their main business, production. But we can’t operate in isolation, and the need to pay more than lip service to environmental requirements has Larger converting become more and more operations supplying big necessary, just as the green contracts are inevitably movements have become exposed to consumer more prominent over the last trends, and anticipating 10 or so years. We found, ironically, that changes in trends can the environmental organisaobviously be useful tions are finding opportunities to create value. Larger converting operations supplying big contracts are inevitably exposed to consumer trends, and anticipating changes can obviously be useful. Sustainability logic can start right within your own manufacturing plant or business, it was pointed out. It may be worthwhile to invite speakers from the PETCO event to give presentations at your company? Read about it on page 36. Besides We have several interesting and relevant articles in this issue besides, including those about the PISA Fire Safety seminar (40-43) in Midrand in February; solutions for the electrical and electronics industries from PlastiChem (78-79); ‘Getting it Right’ (88-89), a column from competition law expert Adams & Adams of Pretoria; design solutions by students at the Tshwane University of Technology (90-91) and much more …

100

90

32

109

INDUSTRY NEWS

™

PlantBottle

at one of SA’s most outstanding

‘greenfield’ projects New plant using naturally-sourced polymers has major ‘green’ credentials COCA COLA’S Valpré PlantBottle™ plant in Gauteng must rate as the most outstanding ‘greenfield’ project yet in the SA plastics industry. The plant is also the first major initiative to use naturally-sourced polymers in South Africa. It is the tenth PlantBottle production plant to be commissioned by Coca Cola internationally and is a major undertaking by the global softdrink group in South Africa, a venture which none of SA’s other big plastics packaging groups would easily contemplate at present, certainly not in the prevailing economic climate. Set in the rolling green hills near Heidelberg, south of Johannesburg, almost dreamlike, you come across the impressive, architect-designed container manufacturing/bottling plant set amid a landscaped environment. Coca Cola has obviously researched the project thoroughly: it achieves what for most converters is close to the ultimate outcome, namely that all input materials, components and preforms enter at one end of the factory and completely packaged, filled and palleted product emerges from the other. Even the road to the plant has been upgraded. The plant marks Coca Cola SA’s first venture into naturally sourced packaging: up to 30% of the material being processed in the PlantBottle™ project is sourced from sugarcane, with the balance of 70% being virgin PET. The ‘renewable’ polymer is sourced from sugarcane ethanol produced in Brazil, which is recognised as one of the global leaders in ethanol sourced bio-fuels. Coca Cola has been sourcing the material from the Brazilian sugar industry for all its global PlantBottle international projects to date. The ethanol in syrup form is converted into glycol in a refinery process by Indian Glycols in India, and then distributed to PET manufacturers in the countries where PlantBottle programmes are underway. The 30% which the sugar-based glycol constitutes of the final material replaces the equivalent amount of monoethylene glycol, 6

APRIL / MAY 2012

which has been used as standard in PET material up till now. The remaining 70% of the material remains terephthalic acid. In South Africa, Hosaf blends the glycol into its Cazeden PET polymerization process at its plant in Jacobs, Durban. The blended material is then supplied to preform manufacturer Boxmore International at Harrismith, and the PET preforms are in turn supplied to the Valpré plant at Heidelberg, situated further up the N3 freeway en route to Gauteng, the main market for the Valpré Spring water produced. The new Valpré plant is situated just kilometres off the N3, allowing for easier access for transport. Other PlantBottle factories around the world – including Brazil, Canada, Chile, Denmark, Japan, Mexico, Norway, Sweden and the USA – have been commissioned over the past two years. Arrangements vary in the different countries, where containers for many of Coca Cola group’s wide range of brands are being produced with PlantBottle material. The fact that the SA initiative involves both a greenfield site development and the use of a ‘green’ polymer is coincidental. But the need for the South African project to be a greenfield undertaking was quite literal: regulations for spring water require that the water be bottled on site. The Valpré plant is situated on top of an aquifer and the water, which originally bubbled from a spring lower down the slope leading off to the plateau that was formerly known as the ‘South Eastern Transvaal,’ is now drawn from below by three pump stations. Increase usage of ethanol According to Casper Durandt, senior technical operations manager at Coca Cola SA, the group aims to increase usage of ethanol and other naturally-sourced materials and will if possible convert its entire process to these ‘bio’ materials. It believes the ethanol sourced material may be priced more consistently than oil-derived material. Coca-Cola’s strategy internationally is also based partly on supporting suppli-

ers where socially inclusive programmes are practised. Given that manual labour is widely used in sugarcane farming, this fits in with the Coca-Cola’s group’s intention to support sustainable activity. Depending on the results of the SA project (samples are submitted to the Coca Cola HQ in Atlanta, USA), other softdrink brands in South Africa may also be switched to PlantBottle technology in the future, said Durandt. Some of the international PlantBottle projects are also using recycled material. In

The Contiform S24 system from Krones of Germany, using 24 stations, can produce up to 24 000 of the 1.5-litre containers an hour, and for the 330ml bottles it churns out up to 40 000/hr.

Ultimate plant for bottles! – The Valpré PlantBottle™ project at Heidelberg near Johannesburg is one of the most sophisticated plastic container manufacturing ventures in the SA plastics industry to date. Besides purchase of the land on which the aquifer on the plant is sited, the capex by Coca-Cola group includes diesel powered generator to produce sufficient capacity to run a plant twice the size, if necessary, as well as a bank of solar panels

On site filling – The containers move directly from the stretch-blow moulding phase to filling, which is completed within seconds of the container’s manufacture. From there sealing, labelling, packing, wrapping and palletising for dispatch are all handled in-line on the Krones system

South Africa the use of rPET from the main local supplier Extrupet has not been approved as yet, due to the fact that the technology utilized at the Extrupet plant is not ‘Coke-approved’. Durandt said, however, that samples of the SA produced material were currently undergoing trialing. Sophisticated line One of the most sophisticated Krones ‘Contiform’ stretch-blow moulding lines in the country is being used to manufacture the bottles. One of the most attractive features

of the line is its quick-change mould system which allows for enhanced and rapid mould changes. At present Valpré is producing 500ml, 1 and 1.5-litre sparkling and still water containers and is making relatively frequent mould changes. With filling on site, the line is designed so as to allow the blown containers to move direct to the filling station, and the filling can be completed within just 2mins of the container’s manufacture. Besides that, application of the closure and sealing, labelling and then packing, wrapping and palletising for dispatch are all handled in-line on the Contiform system. Future plan Coca Cola said in a statement that it is “working with several strategic R+D partners, including researchers at universities and research institutes globally, to advance technologies to extract sugar from plant-based wastes for future generations of PlantBottle™ packaging. So, while we are only using sugarcane today, we expect over the long-term to also be able to use natural resources like stems, fruit peels and bark. Each of these initiatives has a profound impact on our packaging supply chain, which we are literally rebuilding to accommodate the sustainable production and use of PlantBottle packaging.”

www.krones.com www.valpre.co.za

For PlantBottle™ FAQs, go to page 8 ►

Four container sizes are being produced – 330ml, 500ml, 1 and 1.5-litre. Two sets of moulds are employed for the 330 and 500 containers, as the carbonated and still versions have slightly different forms

APRIL / MAY 2012 Notes: India Glycols is one of the leading international manufacturers of glycols using green technology based bulk, specialty and performance chemicals and natural gums, spirits, industrial gases, sugar and nutraceuticals. www.indiaglycols.com

7

INDUSTRY NEWS

™

PlantBottle FAQs Frequently asked questions about the bio-based material programme from Coca Cola group (purified terephthalic acid), which makes up the other 70%. We’ve found a way to make MEG from plants, which is why we say our bottles are up to 30% made from plants. We use the term ‘up to’ because we want to be clear with our consumers around the world that the exact amount of material made from plants may vary some as the bottle production starts up or winds down. Some mixing of bio-based resin and non-bio-based resin can occur as the production lines making the bottles transition between resins, slightly diluting the percentage of material made from plants.

WHAT ABOUT THE OTHER 70%?

The bottling line at Coca Cola’s Valpré PlantBottle™ plant in Gauteng, one of the most outstanding ‘greenfield’ projects yet in the SA plastics industry

WHAT IS PLANTBOTTLE™ PACKAGING AND HOW IS IT DIFFERENT TO A TRADITIONAL PET PLASTIC BOTTLE? PlantBottle™ is our latest breakthrough innovation in packaging. It’s the first-ever fully recyclable PET plastic beverage bottle made partially from plants. The difference is in the materials used to make the bottle. Traditional PET plastic is made using fossil fuels, like petroleum. PlantBottle is made with a combination of traditional materials and up to 30% from plants. Because the end product is still PET plastic, the PlantBottle package delivers the same performance (eg shelf life, recyclability, weight, chemical composition, appearance), but it reduces potential carbon dioxide emissions from our PET plastic bottles and dependence on fossil fuels, like petroleum, when compared to traditional PET plastic.

WHY DO YOU SAY ‘UP TO 30%’ IS MADE FROM PLANTS? PET is made up of two components – you can think of them as ingredients: MEG (monoethylene glycol), which makes up 30% of the PET by weight, and PTA

Currently the other 70% of the PET (the PTA) is made from traditional sources. Our packaging innovation teams are working on technology to develop PTA from plants, but it’s complicated science and we expect it will be a few more years before we have a commercial breakthrough. Meanwhile, in some markets, we’re combining material from plants with recycled PET to enhance the package’s environmental performance. For example, in Denmark, PlantBottle™ packaging is up to 15% made from plants and 50% recycled materials. Our ultimate goal is a carbon neutral, 100% renewable, responsibly sourced bottle that is fully recyclable – a bottle we can all feel good about.

WHAT ARE THE ADVANTAGES OF PLANTBOTTLE PACKAGING? PlantBottle looks, feels and functions just like traditional PET, but it does so with a lighter footprint on the planet and its scarce resources. PlantBottle is fully recyclable in the existing community recycling programmes and can be used back into new bottles or the wide variety of other products made from recycled PET today. It has the same performance as other PET bottles, meaning there’s no difference in shelf life, weight, chemical composition or appearance. Because it’s made partially from plants, it reduces potential carbon dioxide emissions and dependence on fossil fuels compared with traditional PET plastic. Our use of PlantBottle™ packaging in 2010 alone eliminated

almost 30 000 metric tons of carbon dioxide – the equivalent impact of approximately 60,000 barrels of oil from our PET plastic bottles. Another advantage is its ability to strengthen our brands’ connections to customers and consumers. People are responding very positively to the package in each market where it is introduced.

WHERE DOES THE PLANT MATERIAL COME FROM? Currently, PlantBottle is made using sugarcane ethanol from Brazil. Sugarcane ethanol from Brazil is the only first-generation ‘biofuel’ widely recognized by thought leaders globally for its unique environmental and social performance. Most sugarcane in Brazil is grown on degraded pastures located over 2000kms from the Amazon, so it has a lower impact on biodiversity. The farms from which we source use effective cultivation processes, so the sugarcane is predominantly rain-fed and mechanically harvested.

WILL PLANTBOTTLE MATERIALS CROWD OUT FOOD-BASED AGRICULTURE? No. While sugarcane production has increased in Brazil, there has been no drop in food production. Brazil is a leading exporter of beef, coffee, orange juice, poultry, soybeans and sugar. Most sugarcane expansion is on degraded pastures that do not increase competition for new land or displace other crops. Estimates show that sugarcane production in Brazil could increase 30 times without endangering sensitive ecosystems or taking land destined for food crops.

ARE YOU USING GENETICALLY MODIFIED CROPS FOR PLANTBOTTLE? There are no genetically modified crops in the plant materials we are sourcing today. www.thecoca-colacompany. com/PlantBottle

‘Polyglobe’ online database Innovative, inexpensive solution for small and medium-sized plastics converters TO make the planning of plastics purchasing activities more calculable, Plastics Information Europe (PIE), based in Bad Homburg, Germany, recently launched a new online database. ‘Polyglobe’ contains global data on plastics producers, their plants and capacities, forces majeure, maintenance turnarounds, production cutbacks as well as plans for either expansion or closure. The database includes data on plastics and important feedstocks produced at some 3 800 plants across nearly 1 000 sites in 75 different countries. It enables easy evaluations by product, 8

region or company. At producer level, Polyglobe identifies joint ventures and corporate cooperations as well as each producer’s level of integration. Future supply structures are highlighted in 5-year forecasts. Updated daily, the database provides users with reliable information whenever needed. Polyglobe is targeted in particular at plastics converters with strategically aligned raw material purchasing departments, who find the existing products offered by other providers too expensive or too poorly suited to their individual needs.

www.Polyglobe.net

for future generations

st

and using innovative processes to minimise

renewal, harbinger of a 21 Century

environmental impact, our commitment

message – regenerate, renew, recycle.

to quality and sustainability is evident

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the horizon for opportunities to rejuvenate,

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Contact Details: Tel: +27 11 865 8373 info@phoenixpet.co.za

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Maxx Corporate Communications©

The Phoenix, symbol of rebirth and

INDUSTRY NEWS

GBCSA’s removal of PVC minimization clause welcomed THE Green Building Council of South Africa (GBCSA) announcement that the use of PVC products in environmentally-friendly projects will no longer be penalized has been welcomed by the industry. Environmentally-conscious building contractors in South Africa can enjoy the full benefits of PVC piping products, following the announcement from the GBCSA in October that it will remove the MAT-7 PVC minimization clause from its green star tool rating system.

The GBCSA developed the green star SA rating tool to provide the local property industry with an objective measurement for green buildings, and to recognise and reward environmental leadership in the industry. The council initially introduced the clause in 2007 to minimize the use of PVC products in buildings, due to environmental concerns with regards to the formulation, manufacturing process and end-of-life disposal of PVC products. Following negotiations with the South

DPI Plastics will be marketing a wide range of PVC products to green star projects during the course of 2012

African Vinyl’s Association (SAVA), the GBCSA agreed to adopt recommendations to remove the MAT-7 PVC minimization credit in its green star tool rating system, provided that PVC manufacturers adhere to best practice conditions. DPI Plastics in particular is delighted as this is in line with the company vision of ‘pipes for life’. DPI Plastics product manager for pressure pipe systems, Renier Snyman said: “The MAT-7 minimization clause impacted

PETCO 2011 achievements Annual PET recycling rate of 42% of post-consumer beverage PET and 29% of total PET FISCAL 2011 was a momentous year for PETCO and PET plastic recycling in two ways. PETCO celebrated its 6th anniversary and its efforts over the year led to over 1.4 billion PET bottles being recycled across South Africa, close to 4 million bottles recycled every day, exceeding PETCO’s PET plastic recycling rate for 2010 by 5 290 tons. In 2011 PETCO achieved an annual PET recycling rate of 42% of post-consumer beverage PET and 29% of total PET. 42 651 tons of PET were collected and recycled out of a 145 000 ton 2011 resin market. For 2011 the tonnage collected and recycled including pre-consumer was 46 276 tons, representing 46% of beverage PET and 32% of total PET. PETCO benchmark for extended producer responsibility This achievement would not have been possible without the voluntary financial support from PETCO’s members who have all helped PETCO become the benchmark for Extended Producer Responsibility and to bale-by-bale, year-by-year, reduce the volume of post-consumer PET plastic in the

10

waste stream. PETCO also achieved this recycling rate in partnership with contracted service providers, Extrupet, Kaymac and Sen Li Da who combine collection, recycling and end-use in their PET value chain. “Over the past six years we’ve gone from 9 840 to 42 651 tons of post-consumer PET bottles recycled or from 324 million bottles collected in the first year to well over 1 billion bottles recycled in 2011,” said Cheri Scholtz, CEO of PETCO. “We’ve been assisted in the establishment of over 430 plastic recovery stations throughout South Africa and supported training of staff at these drop-off sites. We have also been involved in numerous separation at source and school education projects. We’ve grown our targets from 16% to 46% of beverage PET recycled, from 87 000 to 145 000 tons of PET resin produced, from small to large amounts of recycling levies collected and income opportunities created, from success to success,” she added. Expanded bottle-2-fibre and bottle-2-foodgrade recycling “Our 28 shareholder and 42 associate mem-

bers have contributed to job creation and skills development. PETCO has also provided millions of rands worth of financial support to PET recycling companies and in so doing has managed to expand both bottle-2-fibre and bottle-2-foodgrade recycling. Built on the simple principle of establishing an industry driven and financed environmental solution for PET, the PETCO model is now proven to be expandable and sustainable”, said Casper Durandt, Senior Technical Operations Manager for Coca Cola South Africa, and PETCO Chair. South African PET recycling is unique in that almost all of the post-consumer PET bottles collected are recycled into a local enduse (mainly fibre and more recently bottle-2bottle) and not exported to China, as is done by many other countries. The largest end-use market for post-consumer PET bottles in South Africa is currently the fibre market (bottle-2-fibre). More recently, there is installed capacity for post-consumer PET bottles, to be recycled into new bottles (bottle-2-bottle). B2B resin take-up is, however, still relatively slow and PETCO is working with retailers and brand owners to increase

JUST BRIEFLY

Green Building Council of South Africa CEO Brian Wilkinson

negatively on DPI Plastics’ sales, as contractors and architects would have been avoiding the use of PVC pipes, in order to obtain a four or five star green rating for their building. In the past, any projects that used PVC would be penalised; thereby, significantly affecting their rating in an industry that is becoming increasingly environmentally-conscious.” In late 2011, the GBCSA completed a comprehensive credit review process for the Mat-7 PVC minimization credit, one out of

69 total credits in the green star SA green building rating system. “The GBCSA Technical Steering Committee (TSC) resolved to withdraw the credit after considering the outcomes of the credit review, which involved stakeholder engagement through a PVC Expert Reference Panel and precedents set by other green building councils surrounding the treatment of PVC in green building rating tools,” added GBCSA CEO Brian Wilkinson. Snyman pointed out that the removal of the clause means that the use of PVC products has a neutral impact on the green star rating of a building in South Africa. The neutral rating does; however, only apply to PVC manufacturers that meet best-practice based on the manufacture and recycling of the product. Snyman admitted that the biggest challenge now facing DPI Plastics is to inform and educate the industry of the benefits of the removal of the MAT-7 minimization clause. DPI Plastics will be marketing a wide range of PVC products to green star projects during the course of 2012

Lanpack buys Laughton & Co LAUGHTON & Co, established in 1896, one of the oldest companies in the industry in South Africa, has been bought by Lanpack, a Cape Town company which has been involved in the paper bag industry for over 15 years. Laughton, based in Woodstock, Cape Town, started manufacturing paper bags in the 1890s and went into the production of plastic bags in the 20th century. The purchase thus marks Lanpack’s entry to the plastics market. www.lanpack.co.za

Mpact buys Cape thermoforming Co RA MPACT group has purchased RA Plastics, a thermoforming business in Cape Town. RA manufactures PET, HDPE and HIPS containers. It extrudes its own sheet and employs about 200 people at a 6000m² factory in Blackheath, near Somerset West. Mpact is already involved in thermoforming of polystyrene foam, with its unit Versapak in Paarl being one of the established leaders in that area. However, the new venture in thermoforming of clear as well as coloured sheet signifies Mpact’s entry to a market which has in recent years been dominated by Astrapak. Astra is the SA leader in the thermoformed packaging market, operating both Plastform and Thermopac in Cape Town.

www.dpiplastics.co.za

Renewed BRC accreditation for Extrupet the demand for PET recyclate. 2011 also saw PETCO support projects with a strong focus on public and consumerbased education and awareness programmes and these initiatives and activities contributed to the visible recycling of PET. Together with major retailers Woolworths and Pick ‘n Pay, PETCO has recently established the ‘Retailers for Recycling Forum’ which aims to minimize the environmental impact of post-consumer packaging on the

South African landscape. In 2012 PETCO needs to meet the targeted tonnage of post-consumer beverage PET recycled of 48 356 tons or 44% of all beverage PET resin converted, assist with the establishment of more collection and drop-off centres and progressively build recycling awareness through compelling and focused messaging.

FOLLOWING the annual audit of its manufacturing facilities, South African PET recycler Extrupet has received a renewed accreditation for its foodgrade recycled PET by the sought-after British Retail Consortium (BRC). Extrupet remains the only PET plastic recycler in the world certified by the BRC. www.extrupet.co.za

BASF ups presence in Africa BASF opened a new office in Nairobi, Kenya, in December from where it will service customers in East Africa and the Sub-Sahara region. The company’s target is to more than double sales in Africa by 2020. Its sales, excluding oil and gas, were around €1 billion in 2010. BASF also supports social projects in Kenya, including a project in cooperation with the United Nations Human Settlements Programme (UNHabitat) and local partners. www.basf.com

www.petco.co.za

Nu World exits moulding sector NU WORLD of Johannesburg, one of SA’s top manufacturers of electronic goods and home appliances, has discontinued its moulding operations. JSE-listed Nu World was extremely successful in this area over an extended period, but competing with imports from the Far East has in recent year become increasingly challenging. The company began importing in the early 2000s and was also the SA agent for some top brands, including JVC. At some stages over 600 people were involved in the moulding operations at the company’s premises in Wynberg, but moulding activity has been ceased and at least some of the equipment has already been sold.

South African PET recycling is unique in that almost all of the post-consumer PET bottles collected are recycled into a local end-use (mainly fibre and more recently bottle-2-bottle) and not exported to China, as is done by many other countries 11

INDUSTRY NEWS

Produce real parts rapidly using AMT TRADITONALLY, parts are machined out of a large billet of material by means of CNC (computer numerical control), milling machines, a process known as subtractive fabrication. Using this method, as much as 90% of the original material may have to be removed to produce the finished part. However, there’s a new approach that not only saves time and money, but provides digital accuracy too. Stratasys Additive Manufacturing produces dimensionally accurate parts by adding thermoplastic in layers based on a 3D CAD (computerassisted design) model. The part is built up in CNC profile layers. Stratasys developed and manufactures the patented Fused Deposition Modeling (FDM) systems that manufacture real parts composed of production grade thermoplastics. Because FDM uses real production thermoplastics, parts manufactured are stable and have no warping, shrinkage or moisture absorption like resins and powders in competing processes. No matter how complex, the 3D CAD 12

APRIL / MAY 2012

geometry, Stratasys FDM systems allow accurate production of parts that can be assembled, tested and installed in products for end use. With the advancement of the Stratasys Margie and Russell Oosterlaak, owners of 3D Solids Additive FDM technology Manufacturing Technology (AMT) and the launching of their New FDM range of Manufacturtemperature applications. ing Centre Systems, the FDM 250 MC, 360 With the release of the Stratasys MC, 400 MC and 900 MC systems are now FDM 250MC, FDM 360MC, 400MC and used on assembly lines to produce finished 900MC, it’s no surprise that additive fabparts. Manufacturers use the FDM range to rication systems are being embraced by produce fixtures, assembly tools and special- the design and manufacturing industry. purpose parts in ABS-polycarbonate blend, ABSi medical and food grade thermoplastic, Polycarbonate, Ultem 9085 (Aircraft Grade www.3dsolids.co.za Material) and Polyphenolsulfone for high-

Extrupet rebrands rPET resin Increased installed capacity from 400 tons to 500 tons per month APRIL marked the launch of PhoenixPet, Extrupet’s ‘food-grade’ recycled polyethylene terephthalate resin. In 2009, Extrupet became the ďŹ rst ‘food-grade’ rPET bottleto-bottle (B2B) recycling plant in Africa and to date is the only ‘B2B’ recycler on the continent. Extrupet’s state-of-the-art ‘food grade’ B2B plant is equipped with Erema’s Vacurema technology to supply the market with PhoenixPET, a high quality resin. The plant is the ďŹ rst globally to be certiďŹ ed by the BRC for meeting stringent food safety standards. The reprocessing system was upgraded at the beginning of 2011 when the Vacurema Basic system was reďŹ ned to a Vacurema Advanced system. “This not only allowed for a higher residence time in the vacuum reactors, improving the quality of the material, but also increased installed capacity from 400 tons per month to 500 tons per month, enabling Extrupet to meet the ever growing demand for this environmentally friendly raw material,â€? said Extrupet’s Chandru Wadhwani. “With the generation of a higher IV resin, a greater percentage of the local PET bottle

market has now been able to introduce this valuable material into their stable. Additionally, percentage use of this material when blended with virgin polymer has increased from conservative introduction rates of 10%, to in many cases these days, as much as 50%,� he added. PhoenixPET meets the US FDA’s stringent food safety standards and is used in food packaging by top retailers in South Africa like Woolworths and Pick ‘n Pay. Customers in the bottle-blowing market as

well as the sheet thermoforming market can be assured that PhoenixPET is absolutely hygienic and safe for food and beverage applications. PhoenixPET is produce in two different grades, one with a standard IV for thermoforming uses and the other a higher IV for the use of manufacturing PET bottles. Spec sheets are available from Extrupet on request. www.extrupet.co.za

Extrupet’s state-of-the-art ‘food grade’ B2B plant is equipped with Erema’s Vacurema technology to supply the market with PhoenixPET, a high quality resin

APRIL / MAY 2012 13

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INDUSTRY NEWS

NewLife Plastics develops ‘mitigation’ concept Recycled product developer comes up with new solution Left: Marketing manager Bronwyn Durham with one of the ‘mitigation’ certificates which are presented to buyers of NewLife products

Above left: NewLife team – The management team of the new venture in Cape Town includes Grant Nell, Bronwyn Durham and Roger Thomas (Wayne Brown was out, busy with an installation, on the day)

Above left: Conro Precision, the injection moulding business in Cape Town, is making use of NewLife pallets Above right: Picnic set at the ‘Viper Lounge’ (bikers’ shop) in Cape Town

RECENTLY established NewLife Plastics is developing a new strategy for the plastics recycling sector: encouraging users of plastic products, as well as plastic converting businesses, to purchase items made from recycled material as a positive environmental gesture for which they receive a ‘mitigation’ certificate. The printed certificate outlines how the product is literally giving ‘new life’ to useful resources such as moulded plastic containers, caps, packaging items and a host of other products – items which would otherwise have been lost in the waste stream or ended up in landfill … but are now getting a ‘new life’! The certificate clearly states what quantity of plastic packaging waste has been removed from the environment as a result of the buyer’s purchase. Established in late 2011, the NewLife team includes • Bronwyn Durham, marketing manager, who has spent most of her career marketing plastic products; • Grant Nell, operations manager, responsible for the fabrication of NewLife products; • Wayne Brown, a veteran of the timber home construction sector who now

handles design and projects (on site installations); and • Roger Thomas (consultant), who was general manager at PET supplier SANS until its closure some years ago and who is helping to set-up this new venture. NewLife’s goal is to focus on recycled materials derived from packaging products, and specifically on polyolefins, LD, HD and PP. That excludes PET bottles and containers, polystyrene trays and PVC film. It has so far focused on what are the main established applications for the extruded poles, planks and profiles being produced from the recycled plastic agglomerate. ‘Eco-friendly’ products manufactured include outdoor furniture, decking, pallets, balustrades and even jetties. But the aim is not solely to convince people of the ‘feel good’ factor: the NewLife team is also developing products that genuinely have a good feel in terms of practical applications with smooth contours, slip/scuff resistance, imperviousness to insects and which withstand all weather conditions, in particular harsh the UV light factor in Africa. With the combined input of the fourstrong team, a lot is expected of the NewLife venture. www.newlifeplastics.co.za

Major operational milestone achieved by BASF in PE Facility produces 50 millionth emissions control catalyst for automotive catalytic converters BASF South Africa’s Port Elizabeth Mobile Emissions Catalysts facility has achieved a major operational milestone by producing its 50 millionth automotive catalyst for the catalytic converter industry. Former Engelhard Corporation, in 2006 acquired by BASF, pioneered the development of the first catalytic converters on 1975-model cars, and one year later introduced a second major innovation: the modern Three-Way-Catalyst, which is now capable of destroying over 90% of hydrocarbons (HC), carbon monoxide (CO) and nitrogen oxides (NOx) produced by car engines. The PE business began producing automotive catalysts in September 1994 with seven employees who worked in leased space at the local Ford Engine Plant. Validation of 14

BASF’s Port Elizabeth plant was completed in January 1995, with two approved customers. Increased demand led to capacity expansions until December 2001, when the business moved to a new, larger site in Struanway, where a world-class facility was established. Today, BASF’s Port Elizabeth facility is equipped with state-of-the-art, high-speed, meter-charged coaters. This technologically advanced equipment is used to manufacture Diesel Oxidation Catalysts, Diesel Particulate Filters and Three-Way-Catalysts. Since inception, BASF’s Three-Way-Catalyst technology has, on a global basis, destroyed over one billion tons of HC, CO and NOx before these toxic exhaust gases reached the atmosphere. www.basf.co.za

Mobile Emission Catalysts substrate

Twelve site employees who were employed in the founding year of the plant 18 years ago were recognised for their commitment to the organisation at the event. Here John Maarman, Production Supervisor, receives acknowledgement from Dr Mike Tribelhorn, Site Director

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Medium sized machines for small narrow-necked bottles up to wide-mouthed jars ASB-70DPH / ASB-70DPW Moderate investment costs & mould changeover times, with huge production versatility. Targeted at the medium to large bottle and jar market, while the double row preform configuration is suited for high scale production of bottles under 700ml capacity.

PM-70/65NII / PM-70/111N

Entry level machine ideal for small bottle production with exceptional capabilities ASB-50MB An all-time favourite which is continually upgraded for improved versatility and productivity. Over 1,500 units delivered in the first 9 years of production. PF6-2B / PF8-4B

Leader in PET Technology The histories of Nissei ASB and PET containers have been tied together, as will their future be. Back in the early days of injection stretch blow moulding (ISBM), Nissei ASB was a pioneer in the field and PET was just becoming established as the material of choice for beverage and foodstuff containers. Today, both Nissei ASB and PET remain firmly at the forefront of the injection stretch blow moulding industry. As for the future, no one can predict which direction the industry will take, but there is one thing you can be sure of – wherever it goes, Nissei ASB will be right there at the front continually innovating for tomorrow‌

NISSEI ASB SOUTH AFRICA (PTY) LTD 97 Sovereign Drive, Route 21 Corporate Park Nelmapius Drive, Irene Ext 30 0062 P.O. Box 11785, Centurion 0046, South Africa Tel: +27 12 345 4924 Fax: +27 12 345 5667 E-mail: sales@nisseiasb.co.za

Small and medium bottle production PF6-2B / PF8-4B Capable of moulding containers up to 1.5L (PF84B) and 3L (PF6-2B). Optional neck orientation or preferential heating systems expands the capabilities for extreme oval designs. The PF8-4B is ideally suited to 500ml water or sports drinks containers, while the PF6-2B is ideal for containers in the 1.5L to 3L range. Preform production for small and medium bottle PM-70/65NII / PM-70/111N Ideally matched to the CM and HSB machines for production of hot fillable PET bottles. Also suited to any general moulding operation for a range of performs from 0.3L up to 5L, neck sizes up to 48mm (thread diameter) and from 8 to 24 cavities.

NISSEI ASB PTE. LTD. 85 Science Drive # 01-03 The Cavendish Singapore Science Park 1 Singapore 118259 Tel: (+65) 6778 4633 Fax: (+65) 6778 9440 E-mail: asbsin@signet.com.sg www.nisseiasb.co.jp

AfriMold attracts exhibitors representing the sectors of design, materials, simulation, visualisation, engineering, CAD/CAM/CAE, rapid prototyping and tooling, patternmaking, prototyping, mould-making and tooling, tools, precision machining, machine tools, quality assurance and automation, as well as processing, series production and final part finishing & assembly

INDUSTRY NEWS

AfriMold 2012 during Year of Science AFRIMOLD, the international trade fair for application development via tooling, precision engineering and mould-making will take place from AfriMold managing 10–12 October director Ron at the Gallagher MacLarty Convention Centre in Midrand, South Africa. The organisers of AfriMold are pleased to announce the official endorsement of Plastics|SA. According to Anton Hanekom, Executive Director of Plastics|SA, plans are underway to create interactive features and visitor attractions at this year’s expo. “The opportunities at AfriMold are vast - from part design and material selection

to testing and final injection moulding of the finished part, AfriMold will cover the sectors of automotive parts, engineering parts, medical instruments, packaging for food and beverages, paint and chemicals, as well as personal care products and more,” said Hanekom. The trade fair attracts exhibitors and visitors representing the associated sectors of design, materials, simulation, visualisation, engineering, CAD/CAM/CAE, rapid prototyping and tooling, patternmaking, prototyping, mould-making and tooling, tools, precision machining, machine tools, quality assurance and automation, as well as processing, series production and final part finishing & assembly. According to AfriMold managing director Ron MacLarty: “The specialised nature of AfriMold attracts a highly targeted audience

of visitors, who are for the most part proactive buyers. The expo’s visitors have made a conscious decision to purchase and have set aside valuable time to attend the expo and do just that.” Past research has shown that AfriMold visitors do come with very specific goals in mind. Among the more common reasons are, to: see what’s new; evaluate products and suppliers; keep abreast of industry and market developments; network and develop business contacts; consolidate business relationships; solve specific problems; find new markets; appoint agents and seek principals; discuss terms, conditions and pricing; and obtain technical knowledge. This year’s AfriMold trade fair runs in conjunction with the German/South African Year of Science and as such the conference content, in particular, will be expanded to address the role of science in elevating current practice to the domain of leading economies. The conference theme is ‘Tooling as a Key Enabler for the South African Manufacturing Sector – Climate Change Mitigation’, and will feature topics central to the Year of Science (YOS). It will explore opportunities to mitigate climate change via smart manufacturing. www.afrimold.co.za

PISA student design competition tackles rural problem Judges looking for winning concept solutions for rural transportation of recyclables PLASTICS/SA, Plastics Converters Association (PCA) and the Plastics Institute of SA (PISA) will host a student design competition at AfriMold in October. The competition is being held during the German/South Africa Year of Science, focusing on climate change and human capital development. The Fraunhofer Institute for Surface Engineering and Thin Films and the Fraunhofer Institute for Transportation and Infrastructure Systems will provide students with the opportunity to engage with the institute’s specialists should their technologies be identified for incorporation in the students’ concepts. So far, the Innovation Hub in Pretoria has been secured as a sponsor and as ‘techni-

cal adviser’ helping with the finalization of the design brief to students. Judging will take place during the Plastics│SA Conference at Gallagher Estate during AfriMold from 10-12 October. It is envisaged that the winning concepts will also be exhibited at Euromold in Frankfurt, Germany, from 27–30 November. Background There is a major need in South African rural areas for a mode of transport for the rural poor to collect recyclable material and transport it to a collection depot. The SA plastics industry has made major inroads in the collection of plastic waste and has established a successful recycling industry. The project

needs to be extended to the rural areas to prevent pollution and provide opportunities for entrepreneurs to establish themselves, also providing a vital service to the community. Students are encouraged to come up with concept solutions for a vehicle or trolley that would assist in the collection and transportation of recyclable materials in rural areas. Entries must include concepts for mobility, be it human, electric, biogas or solar powered. The liberal use of plastics is encouraged, specifically if the concept mitigates mass manufacture and needs to be light weight in construction. For more details, contact Douw Steyn at Douw.Steyn@plasticssa.co.za

A collection of clever rural transport solutions – they may be lacking in finesse, but they get the job done! 16

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‘Lockit’ for your favourite drink Device puts a stop to unwanted gulping

• OSCAR KOEN: PHONE 078 357 8803 A prototype of the ‘Lockit’ – in this case minus the lock (in order to show the design) – which was cut from a solid block of ABS

SAPPMA completes 2nd round of quality tests Plastic pipes show improved quality, but still room for improvement THE quality of plastic pipes manufactured in PVC pipes at random from eight different South Africa leaves room for improvement, manufacturers – all of them carrying despite the fact that many of the pipes carry the SABS mark (SANS 1601, SANS the SABS mark of approval. 966-1, SANS 966-2 & SANS 967) and According to Jan Venter, CEO of the clearly identified by trade- or company Southern African Plastic Pipe Manufacturers names. Of those pipes tested, at least Association (SAPPMA), the results of the 56% of those produced by non-SAPPMA second round of random sampling undermembers failed, whilst none of those taken by SAPPMA since the first sampling produced by SAPPMA members failed”. exercise of a specific range of products took After the results of the first round of place last year, have just been released. tests were released, SAPPMA repeated “SAPPMA works the survey at the very closely with the end of 2011 – Long-term product SABS in a joint effort again obtaining quality is fundamental and to weed out inferior pipes at random, quality plastic pipe should quality plastic piping although a much systems,” Venter be good for a minimum bigger sample size said. “It is our vision to was used. period of 50 years create absolute qual“We have found according to industry ity, trust and integrity that a considerstandards. throughout the value able number of the chain of the Southern pipes tested still fell African Plastics Pipe Industry”. short of the industry standards. HowBecause the plastics piping business is ever, we are pleased to report that there a strategic industry, hardware needs to be seems to be a significant improvement reliable for extended periods of time. Longsince the previous survey”, Venter said. term product quality is therefore fundamenWhilst SAPPMA does not claim that tal and quality plastic pipe should be good all pipe produced by its members will for a minimum period of 50 years according be 100% faultless all of the time, Venter to industry standards. pointed out that the results of the first “However, the plastic pipe industry finds round of tests do seem to indicate a itself in an increasingly difficult position due trend with regards to the setting of and to economic pressure. In a situation such as adhering to industry standards. ours where supply continually exceeds de“In the interest of the consumer and mand, manufacturers are looking for ways the long term integrity of the infrastructo cut costs, which often impacts negatively ture, SAPPMA will continue with these on product quality”, Venter explained. market surveys. We are confident that To ensure industry compliance and high independent tests such as these will standards throughout, SAPPMA launched increase the public’s awareness of quala random sampling exercise of a selection ity issues, which will ultimately raise the of pipes obtained at random from various level of responsibility of manufacturers,” stocking merchants at the beginning of Venter added. 2011. The dimensions and stiffness of these pipes were tested at a certified independent laboratory in terms of the relevant SABS standards. “The results were rather shocking”, www.sappma.co.za Venter said. “We selected 18 samples of 18

APRIL / MAY 2012

INDUSTRY NEWS

TIRED of having colleagues drink the water from his special chilled supply in the workshop fridge, Cape Town tool maker Oscar Koen got to work. His goal was to design a device that would prevent theft from the Oscar Koen, develcontainer. The result: oper of the ‘Lockit’ bottle device the ‘Lockit’ moulding that effectively prevents removal of the lid from the container, and hence theft of the contents. His brainwave resolved the problem in a flash, and also resulted in Oscar getting some puzzled glances from colleagues at his workplace in Paardeneiland. He has since been spurred on by the potential to commercialize the product. Oscar believes his design could be used at schools and workplaces around the country. In fact, it could be used wherever individuals in large groups seek to prevent others from accessing, unsolicited, their choice of beverage, when left unattended that is. In Oscar’s case, drinking water during the hot summer days, and even hotter temperatures in most toolrooms, is a necessity. To many, removal of water – the ‘elixir of life’ – from a container in a fridge can hardly be constituted as theft, but many may share his reluctance to accept such activity. The design may quite possibly have a role to play besides: preventing others from drinking from one’s personal container could even be a reliable health strategy – by stopping the spread of oral viruses, said Oscar, who has been involved in toolmaking for over 30 years. Now Oscar believes the gimmick could, besides its safety features, be used by beverage manufacturers for branding and could be an attractive ‘value-adding’ feature for softdrink and mineral water suppliers.

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ADDIVATION:

One-stop consultancy for additives

Tim Cooper is putting over 30 years’ experience in the area of additives to work at his new company, Addivation, based in Johannesburg

ADDIVATION, a new company aiming to become a one-stop consultancy for plastics additives, has been launched by Tim Cooper. Cooper has 36 years’ experience in the plastics additives game, from analysis, formulation, research and product development, to production, sales and marketing of plastics additives. He started his career in the mid-1970s with what was then AECI, as a lab technician analyzing the content of additives in polyethylene. From there he moved to Resinite, and after a stint in R&D, took over full technical management, including production, of thin films in rigid and flexible PVC and polyethylene. He joined Ciba-Geigy in 1986, where he set up and managed the local technical service laboratory, before moving into

marketing and sales. Cooper continued in marketing and sales of a broad range of plastics additives as director of Chemfit, which he and his partners sold to Chemserve in 2008. Recently Cooper decided to change his career path, and with years of experience in a wide range of plastics additives disciplines, formed his own consultancy. “In a world where plastics are increasingly replacing traditional materials such as metals, wood, glass and paper in the whole spectrum of applications, from packaging to automotive, electrical and electronics to mining, domestic to agriculture, just to mention a few, the requirements for additives becomes more demanding. “With more and more suppliers in

CTP Flexibles installs 3 more slitter rewinders CTP FLEXIBLES, the Cape Town based converter of flexible packaging materials made an exciting start to 2012 with the arrival and installation of three 1350mm wide Titan ER610 compact slitter rewinders. The first Titan slitter will be installed during January with the second and third machines following closely behind. Recently, CTP Flexibles has seen a dramatic increase in its customer base and also in the demand for its flexible packaging materials, so much so that its slitting capacity has been placed under tremendous pressure – hence the decision to invest in three new Titan ER610 slitters. “With the three new Titan slitters we will 20

APRIL / MAY 2012

have ample capacity to cope with both current demand and also future expansion of our business,” said Gary Seale, MD of the company. “We had already installed one 1650mm and one 1350mm wide Titan ER610 slitter during 2010, which gave us every confidence to invest again with Titan,” he added. CTP Flexibles manufactures specialised plastic extrusion and flexible packaging for the food, beverage, confectionery, industrial and general merchandise industries. With leading technology and part of Caxton & CTP Publishers & Printers Ltd. the company has been producing and converting packaging for South Africa’s blue chip companies since 1971. “We produce everything here,” Gary Seale

explained. “We extrude high-density, lowdensity and linear low-density polyethylene films and produce cast polypropylene films. We also manufacture a comprehensive range of sophisticated products – from laminations, multi-layer films and shrink films to bags, pouches and shrink sleeves.” The Titan ER610 compact slitter rewinder has been a great success worldwide for Atlas Converting Equipment Ltd. with sales of more than 100 machines worldwide. It is available in 2 web widths, 1350 mm and 1650 mm, with a maximum rewind diametre of 610 mm. The Titan ER610 slitter can process a wide range of flexible materials including plain, printed, coated or metallized film from 20 to

INDUSTRY NEWS

the market, the choice of additives also becomes more bewildering. How do you know you have the right additives to meet specifications, and at the right price? That’s where Addivation can help. We know what combinations of additives work and what combinations do not,” added Tim. Addivation has experience in a wide range of additives types, including antioxidants, light stabilisers, heat stabilisers, processing aids, anti-static agents, anti-fogging agents, slip and anti-blocking agents, plasticisers, fire retardants and smoke suppressants, nucleating agents and fillers, foaming agents and crosslinking agents, to name just a few. Addivation also offers a wide range of services, including: • product development, including provision of technical recommendations, sampling, trials and tests to meet required specifications; • training courses on all aspects of plastics additives;

• applications testing to verify performance according to specific specifications; • analytical testing of additives to verify level of addition and issue of quality certificates; • product failure analysis and representation as expert witness in case of disputes; • assistance with advice on production and dosing of specific additive packages; • productivity improvement and cost reduction programs of existing products; • assistance with patenting of novel ideas and new novel products; • quality control testing of masterbatches and compounds; and • participation in ‘round-robin testing’ of additives. Addivation has already invested in its own laboratory equipment and will be extending its facilities in the coming months. • CONTACT ADDIVATION ON 078 768 7571

200 micron, a wide range of laminates and paper from 30 to 200 gsm at speeds up to 450 m/min. The minimum slit width can be as narrow as 25mm.

The Titan ER610 slitters - CTP Flexibles has seen a dramatic increase in its customer base and also in the demand for its flexible packaging materials, so much so that it is installing three new Titan ER610 slitters

www.atlasconverting.com

www.ctpflexibles.co.za

‘AQUALOK’ SAVES WATER Seeking a solution to prevent water theft from exterior taps led entrepreneur Lionel Brown to his local hardware store, but he left frustrated: the steel tap lock covers on offer appeared to be either highly overpriced (at R50-R125) or, for the cheaper versions, sold out. The metal versions were also liable to rust, and could also fall prey to scrap metal collectors. Originally from Port Elizabeth but now resident in Amanzimtoti, KZN, Lionel has since that experience in 2007 developed his own version, the ‘Aqualok,’ which is a far more cost-effective solution. “Once you have fitted a plastic tap and plastic tap lock, it really becomes worthless to be stolen, and is effectively a deterrent,” said Lionel. Home-owners will easily become aware of any water theft – and possible rising water bills. Advantages of the injection moulded component include assorted colours for various water grades and the fact that they are inexpensive (retail at under R25) and UV protected. Organic colours are also available, meaning that the Aqualoks blend in with undergrowth, which can be a further deterrent. • SHOULD YOU HAVE ANY QUERIES, CONTACT LIONEL AT IONLLE@YAHOO. COM OR CALL 072 311 1429 APRIL / MAY 2012 21

INDUSTRY NEWS

Joesten now represents combined Maag, Automatik entity SA supplier adds specialist pelletising technology to its range JOESTEN of Johannesburg, a supplier of high performance material processing solutions, is now also supplying a comprehensive range of pelletising equipment following the merger of its principal Maag Pump Systems of Switzerland with Automatik Plastics Machinery of Germany. Joesten has represented Maag for some years. A number of the Swiss company’s gear pumps, filtration systems and screenchangers are in operation at polymer and rubber processing, extrusion and recycling plants around the country. Now, with the Automatik-Maag merger, it also offers pelletising systems, as such giving it a complete range of equipment for material processing. Automatik Plastics Machinery was founded in 1947 and specialises in strand and underwater pelletising systems. With its headquarters in Grossostheim, Germany, the company was previously present on the market as Rieter-Automatik; it has about 220 employees.

Maag has its headquarters in Oberglatt, Switzerland, and is based on the gear company founded in 1913 by Max Maag. It manufactures equipment for demanding applications in the plastics, chemical and pharmaceutical industries; it has about 240 employees. Through their merger, the companies’ combined turnover in 2011 was estimated at €130-million and their on-site global presence has been nearly doubled to 100 countries. Tienie van Staden of Joesten in Johannesburg said he believed the high standard Automatik-Maag machinery was suited for very high as well as low throughput applications, making it suitable for small operators as well as large production plants where manufacturers need reliable equipment capable of 24/7 operation with reduced maintenance. Complementary ranges Automatik and Maag had been working together on projects for different customers for a number of years. The

As one of the world’s leading providers of pelletizing technologies for all pellet shapes, Automatik of Germany supplies all kinds of pelletizing solutions for standard applications involving commodity polymers and technical thermoplastics. It has recently supplied tailor-made solutions for the processing of, among others, biopolymers, PET as well as recycled PET, micro pelletizing and fibre-reinforced thermoplastics

merger is a logical consequence of the complementary product ranges of the two companies. “With the merger, we can offer customers high-quality components and complete, integrated systems for plastic processing. We are one of the largest providers in this segment worldwide,” said Ueli Thürig of Maag, new CEO of the group. The plant at Grossostheim in Germany will serve as a central location for the installation of complete systems, repairs and services. “The location in Germany is ideal, since many of our OEM partners for plastic processing also have their headquarters here. We can offer complete system integration consisting of gear pumps, screen changers, pelletising systems and automation units from a single source,” added Thürig. Besides Germany, the group operates four other production locations in Switzerland, Italy, the USA and China. Assembly is being further expanded in Shanghai. • JOESTEN, PHONE 011 915 3269 www.joesten.co.za

NOTE The merged companies are owned by Dover Corporation, whose Pump Solutions Group (PSG), a global leader in positive displacement pump and supporting technologies, purchased the shares in the businesses in February from the previous owners, CGS Management of Switzerland and Clyde Blowers of Scotland.

www.maag.com 22

APRIL / MAY 2012

www.pumpsg.com

a brand of maag group

a brand of maag group

a brand of maag group

Joesten International P.O. Box 3208 1540 Brakpan South Africa

international@joesten.co.za T. +27 (11) 915 3269 F. +27 (11) 915 3267

INDUSTRY NEWS

Thermopac installs new System from GN of Canada offers energy and production scrap minimization Canadian company’s biggest yet, and also WITH the focus of thermoforming technolthe first of its kind in Africa. ogy having shifted in recent years to more To meet ever-changing customer deversatile solutions which offer both scrap mands and high quality requirements, Therand energy minimisation, Thermopac has mopac had identified installed a system from its prime machine GN of Canada which Optional chamber needs as systems meets all these requirepre-heater enables which are economical ments. Thermopac to produce to run, which generate Part of the Astrapak both mono and multi-layer the least amount of group, Cape Townproduction scrap and PP containers based Thermopac is offer in-mould cutting, one of SA’s top thermoas well as low mould costs. formed container manufacturers. It has up Thermopac has been increasing usage to now used a number of smaller machines of GN’s type of technology for some years. from GN Thermoforming, whereas the new The GN machines generate very low wastsystem – the GN 760 thermoformer – is the Eugene Fisher (master setter), Melanie Williams (electrician) and Catherine Voigt (production manager) during commissioning of the new machine at Thermopac in Elsies River

Bright future for thermoforming in SA We spoke to Tim Forshaw of BRE Sustainable Packaging, the agent for GN Thermoforming Africa, about the new GN 760 system … What are the main technical advantages of the system? The GN 760 is a plug-assisted thermoformer with cut-in-place tooling that has three main advantages: Tim Forshaw of BRE Sustainable Packaging 1. Material wastsays the thermoformage is reduced by ing industry in South 5-25% compared Africa has been growing to a form-cut-andsteadily at 5-10% p/a for an extended period stack system. The cutting system allows smaller gaps between the products: normal machines have 12mm gaps whereas, the 760 has already run product with 7mm gaps. One customer has developed tooling with a common knife edge in the machine direction, eliminating all scrap between the cavities. This is a significant advantage because material is approximately half of the cost of a thermoformed product; 2. Electrical power required to run the machine is 35-50% lower than competing equipment. This is achieved by using an energy regeneration system in the sheet heating, as well as the use of servo drives for plugging, material transport, stripping and stacking. GN measure savings in energy of $9000 per year for this advantage; 3. Tooling costs for cut-in place tooling can be very high. GN 760 tooling uses the forged 24

APRIL / MAY 2012

knife or steel rule and cut plate which significantly reduces the tooling cost compared with traditional punch-and-die systems. The alternative cheaper tooling of form-cut-andstack generates higher waste and energy costs which outweigh the gains of lower tool cost. Is the manufacture of larger machines a new area for GN? GN has for many years produced machines in its contact heat range with large forming areas, 1180 x 813mm being the largest. In the plug-assisted radiant heat technology, GN produced some smaller format, 320 x 150mm tilt mould machines for many years and about seven years ago started building an intermediate size machine, 480 x 355mm. The 760 forming area is 760 x 530mm, which is comparable with many of the larger machines on the market. It is certainly the most technically advanced machine from GN. How flexible is the machine, in terms of mould change times for short production runs? The tools can be changed by an experienced operator in less than an hour. This is very quick for such a large format machine. However, we do not see this as an important selling point as most users will be running long production runs on this type of machine. Despite its relatively low tooling cost, the GN760 is not an ideal machine for short-run

production: we recommend other alternatives for that sort of production requirement. In what way is the machine particularly suited to local conditions? All GN machines are built with durability and low maintenance costs in mind. The simple-to-use GN760 has a user-friendly control system and advanced diagnostics which permit easy troubleshooting, and the machine can be connected to GN for electronic diagnostics. The machine has an inbuilt robotic stacking system. A split conveyor for transporting stacks allows the operator to empty the conveyor without disrupting the stack count. GN also has a spares supply capability which is unmatched in the industry, meaning less downtime for customers. What is BRE’s view of the future of the thermoformed plastic packaging sector in SA? Thermoforming of packaging is the most cost effective process for many rigid products. The thermoforming industry in South Africa has been growing steadily at 5 to10% per year for many years. The most successful thermoformers are the companies with appropriate and up-to-date equipment. With the advantages that we can offer to thermoformers with the GN products and complementary materials, there is certainly a bright future for thermoforming in South Africa.

thermoforming technology age and consume relatively small amounts of electricity compared with conventional radiant heat machines. However, the technology was also limited in its ability to produce certain types of containers. GN has as a result introduced the energy-saving, radiant heat, plug-assist machine, combining these features with its forged knife in-mould cutting system. The new technology will allow Thermopac to produce containers with identical proďŹ les at high speed and with energy consumption of approximately one-third that of other radiant heat machines. The GN 760 has a unique energy regeneration system, as well as an in-built robotic parts stacking system that minimizes labour cost. This GN 760 is equipped with an optional chamber pre-heater to enable Thermopac to produce both mono and multi-layer polypropylene containers. The market for ambient shelf

stable products in plastic containers is undeveloped in South Africa. Containers for these products, normally metal or glass, can be thermoformed from barrier PP material which can be heat sterilized after ďŹ lling. Thermopac will now be able to produce

these containers with the most up to date forming technology. • THERMOPAC, CONTACT MICHELLE PETERSEN, 021 592 1100.

The GN 760, one of the largest thermoforming systems from Canadian thermoforming machine maker GN, has an in-built robotic parts stacking system that minimizes labour cost

APRIL / MAY 2012

25

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The GN Advantage Delivering Bottom Line Results

Email: tim@bre.co.za

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W e b s i t e : w w w. b r e - i n n o v a t i o n s . c o . z a

Transpaco installs hi-tech recycling system for PP & BOPP film

EQUIPMENT

Capacity extended to well over 1 500 tons a month TRANSPACO Recycling has recently installed one of the most sophisticated systems available for the reprocessing of polypropylene and heavily printed and metallised BOPP films. The TVEplus recycling system from Erema of Austria is being used specifically for the recycling of PP and BOPP films, a category which up till now has lagged behind tonnages of the mainstream polyethylene materials being recycled. Transpaco Recycling is already one of the biggest recyclers of low-density PE in South Africa, including a significant portion of post-consumer LDPE material. In excess of 1 000 tons a month of postconsumer plastic waste are being received and reprocessed at the factory near the airport. The new investment will see capacity extended to well over 1 500 tons a month. “There’s a huge amount of plastic waste that’s still being sent to landfills,” said Transpaco Recycling MD Jaco Breytenbach. “We’ve been highly successful at PE recycling but, although we’ve received numerous inquiries regarding specific recycling of PP and BOPP factory scrap, we’ve had to turn many people away because we haven’t had the technology to deal with it,” he added. Clean factory scrap such as plain, printed, metallised and laminated BOPP and PP films are targeted. “I’m happy to say we can start collecting a host of different plastics. For us, it’s a real breakthrough, because we’re not only meeting customer expectations, but also assisting in reducing the waste content at landfills.” According to Breytenbach, the Erema

TVEplus system supplied by Erema (Austria) and supported by local Erema agent Relloy, cost an estimated R8-million, but is the best in its class and ideally suited for the local market. “Once we decided we were going to invest in specialised recycling equipment, we wanted to have the best equipment for the job. Customers require a clean, consistent recycled granule every time and the TVEplus will ensure that this is what they get,” he added.

www.transpaco.co.za consumption by up to 10% as well as production costs and CO2 emissions. The equipment has proved easy to install and commission and Transpaco’s operators have embraced its modern technology very quickly, receiving full training from local agent Relloy SA.

Local solution Transpaco can receive stock from factories anywhere in the country. Factory scrap can either be collected by Transpaco or delivered directly to the Elandsfontein site. Leader in recycling technology Sellers are offered a price per kilogram rate The latest in the highly-successful TVE by Transpaco for the scrap material. “We’re series, the TVEplus features high-perforpart of the multi-national Transpaco Group mance degassing, thorough melt homoge- that ensures our flexibility and sound finannisation and ultra-fine filtration. A special cial backing,” said Breytenbach. “Our aim cutter-compactor includes a patented is to give the best service possible in order Double Disc (DD) technology that enables to recover as much waste as we can. Cusmaterials with up to 12% residual moisture tomers can be confident that we’re working to be processed, with consistently high with them to find the best solution to their output. An ‘Air Flush Module’ increases waste problem and that we’re producing a drying performance while ensuring lower high-quality recycled material.” energy consumption and extended plant Transpaco Recycling follows a strict QA service life. programme and all recycled materials must Benefits include enhanced filter peradhere to a strict COC standard. Some of formance (thanks to reduced shearing the reprocessed PE material is currently upstream of the melt filter), optimised triple sold within the Transpaco group, but the degassing with the patented cutter compac- majority of the capacity is sold to plastic tor, optimum screw design and extruder packaging converters across sub-Saharan degassing for highly effective degassing of Africa. It is anticipated that the recycled PP the filtered melt and high homogenisation and BOPP will be sold mainly into the injection moulding sector. efficiency downstream of filtration and upstream of degassing, which enhances the “It’s in the converter and brand owner’s subsequent degassing performance and interests to start recycling practices and the improves the characteristics of the melt. environmental benefits are huge, as well The TVEplus features ‘ecoSAVE’ as an answer to their Extended Producer components which reduce overall energy Responsibility,” added Breytenbach.

On the BOPP! – The new Erema TVEplus system which has been commissioned at the Transpaco Recycling plant in Elandsfontein, Johannesburg, is being used specifically for the reprocessing of clean factory waste such as plain, printed, metallised and laminated BOPP and PP films

26

Fresh Start for PP and BOPP Recycling in SA

Transpaco has installed an ultra-modern Erema TVEplus recycling system to handle clean polypropylene, heavily printed and metallised BOPP ďŹ lm

Send your clean factory PP and BOPP waste to Transpaco for recycling We are your link to Extended Producer Responsibility

5

Transpaco PP Recycling 180 Barbara Road, Elandsfontein, Germiston Tel: (011) 822-6470 | Fax: (011) 822-6475 Elmien.Roux@transpaco.co.za www.transpaco.co.za

LEADERS IN RECYCLING FOR A GREENER FUTURE

INDUSTRY NEWS

A fusion of extraordinary companies PlastiColors, Banbury combine 50 years’ colour experience in plastics industry PLASTICOLORS and Banbury Chemicals have joined forces to leverage a natural synergy that exists between them: masterbatch and dosing machines go hand-in-hand. PlastiColors has been a pioneer in the local masterbatch industry for over 35 years. Renowned for its technical innovation and unsurpassed quality, it has built a reputation as a preferred supplier of colour masterbatch, pigments, liquids and

additives. PlastiColors was also the first masterbatch producer in South Africa to achieve the ISO 9001 accreditation by the SABS, a standard accreditation which the company still maintains. “We have perfected the manufacture of polyethylene-based masterbatches for injection moulding, blow moulding and extruded film, as well as polypropylene and polystyrene based materials. We are currently at the forefront of industry development of so-called ‘engineering’ type materials – for ABS, acetyl, PET, PBT,

Movacolor solution – The ‘MC-Balance’ doses directly into the virgin material stream at the machine throat, which eliminates the need for batch weighing as well as the need for a mixing chamber, a system which reduces masterbatch consumption by 20-50%

polycarbonate and polyurethane,” says Michael Maine, operations director at PlastiColors’ head office in Sebenza, Johannesburg. PlastiColors exports product throughout Africa, the Indian Ocean islands and to other international companies. Local agents are conveniently situated in Mauritius, Harare, Pinetown and Cape Town to provide excellent service to surrounding plants. Banbury Chemicals – synonymous with the world’s leading brands Established in 1996, Johannesburgbased Banbury is made up of a father-and-son team, Brian and Dean Sinclair, who collectively have more than 38 years’ experience in the plastics industry. Banbury specializes in the importation of UV stabilizers, anti-oxidants, pigments and automatic dosing machines. It is a primary agent for world leaders in the plastics industry such as Holland Colours, Addcomp, Songwon, Metaflake, Movacolor and Hubron. Banbury distribute its products to polymer producers, compounders and plastics converters. For many years, Dean Sinclair witnessed frustrated plant managers battling with inaccurate mixing and dosing processes in their extrusion lines. He recognized the need for quality dosing machines, and Movacolor dosing machines were the natural choice – a single component gravimetric dosing unit developed by Movacolor BV of Holland. Dean explains: “Movacolor’s gravimetric dosing system reduces masterbatch consumption by 20 to 50% and features some unique elements that won’t be found anywhere else. This is proven by the fact that the ‘MC-Balance’ doses accurately at all times through continuous loss-inweight measurements in combination with a closed-loop control of the dosing speed. It automatically adjusts Continued on page 30

28

APRIL / MAY 2012

PLASTICOLORS

YEA YEAR YE Y EAR ARS ARS

;ijWXb_i^[Z '/-,

Extraordinary

fusion

[PlastiColors and Banbury Chemicals combine to take the industry by storm]

When moisture and light meet, something extraodinary happens – the entire spectrum appears in a glorious display of colour. In this spirit, as leaders in masterbatch, pigments, liquids and additves, we have partnered with Banbury Chemicals, specialists in the importation of UV stabilisers, anti-oxidants, pigments and automatic dosing machines. Our mutual focus and single-minded pursuit of perfection in colour and www.jhafrika.co.za 23118

consistency brings a new horizon to the plastics industry.

Excellence keeps good company

Tel: +27 11 452 6940 | Fax: +27 11 609 5960 | email: info@plasticolors.co.za | www.plasticolors.co.za

M A S T E R B AT C H

P I G M E N T S

L I Q U I D S

A D D I T I V E S

INDUSTRY NEWS From page 28

Brand new partnership – Michelle Maine Fleming and Michael Maine of Plasticolors and Dean Sinclair and Brian Sinclair of Banbury Chemicals who have formed a partnership to supply Movacolor dosing technology as well as distribute PlastiColors’ colour range in the Western Cape

the dosing time to the speed of the injection moulding machine or the and the percentage addition rate need to be entered. extruder. Also, vibrations of the production machine are automatically When operators want to change some data, the compensated for.” user-friendly control panel enables an authorized user It’s important to note is that the MC-Balance system doses directly to do so. All settings and changes are recorded into the into the virgin material stream at the machine history file and stored. This inforthroat, which eliminates the need for batch weighmation cannot be interfered with. This brand new ing, and the need for a mixing chamber. Many Stored information helps manage partnership offers plastics processors, who at first thought that they needed quality control data. converters the best of both an expensive blender for their application, have now discovered that the MC-Balance perfectly A unique partnership worlds: An accurate and suits their needs. Dean faced one last problem: recreliable dosing machine The MC-Balance ensures the user of accurate ommending a quality masterbatch paired with superior dosing, which can save up to 50% on expensive for his dosing machines to perform quality masterbatch. colourants. The unit’s self-adjusting capabiliat their optimum. Since Banbury ties ensure staff don’t have to interfere with the has been supplying PlastiColors gravimetric unit settings, which results in downtime being reduced to with additives for over 15 years and had testimony of an absolute minimum. Setting up is very easy, as only the shot weight PlastiColors’ superior quality, the solution was simple. This brand new partnership offers plastics converters the best of both worlds: An accurate and reliable dos30 APRIL / MAY 2012 ing machine paired with superior quality masterbatch, which together ensure scrap rates and downtime are minimized, the consumption of colourants are optimized, and the consistency and quality of the converter’s end product is unequalled. PlastiColors has been expanding capacity to handle increased n demand says financial director, Michelle Maine Fleming: “Toward the end of 2010 it became apparent that the demand for our product was growing THE ONLY INTERNATIONAL MOULD TEXTURING rapidly, and we needed to expand in order to meet COMPANY IN SOUTH AFRICA our customers burgeoning orders without sacrificing our quality. We immediately made plans to expand j~{ i w z{ [ } w } ] © i {y w ~{ { } | c z B our plant building by 40%, as well as import four new ~w x{{ w z } | y{ ~{ f w { w z h { production lines.” ¢ { z | y {~{ { B w {B © bw }{ ] xw x w | w { This foresight was 20:20: “We are expecting an even w z z { } w } | { NF © ] xw W { f {y w z {w ¤ w z {wz{ w } f {y cw w}{ { stronger growth in 2012 as a direct result of our part { { w w { | |wy{ © W z } w { w y z } y { nership with Banbury Chemicals, and we are ready!” | { w {B w y B ~{ B {{ w z { x z } z y B { {B w { B © _ { w w {y~ yw i Cape Town agent y { w z y y © Z{z yw {z h<Z Z PlastiColors has also appointed Banbury Chemicals w yw D © Wyy{ w { | ~{ w Z } w w z as an additional Cape Town agent in order to better bw { f y{ } © fw | w } xw { | IJ w service the Cape plastics industry and surrounds. w {z [ {B W| ywB _ z wB W w Banbury has already set up shop and is operating w z ~{ W { yw D full steam ahead. The new premises are at 72 Manhattan Street, Airport Industria, which is close to the airport and the main thoroughfares and hence an ideal platform to the Western Cape market. With the fusion of these industry-leaders, customers will benefit from 50 years’ combined expertise and shared dedication to excellence – a dynamic partnership that is poised to take the industry by storm. CONTACT US: Standex Engraving South Africa | P.O. Box 83, Umlaas Road, 3730 Tel: 031 785 1247 | E-mail: dan@standexsa.co.za www.mold-tech.com / www.standex-engraving-design.com

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Southern African Plastic Pipe Manufacturers Association (SAPPMA)

IFPA chairman Mike Smart (centre) with, from the left, Dawie Fick, who has been involved with IFPA since its formation, and the group’s other board members, Wanda Bester, Jan Venter and Ralph Mosikidi

Director Jan Venter p. 012 548 0149 c. 079 506 0484 e. janventer@3gi.co.za

Secretary Louise Muller p. 012 548 0149 c. 082 417 2977 e. admin@sappma.co.za

www.sappma.co.za

IFPA elects new board members

ASSOCIATION NEWS

Ensuring high standards of plastic pipe fabrication and installation THE Installation and Fabrication Plastics Pipe Association (IFPA) has elected its new board members for 2012. Dawie Fick of Customised Plastic Products, Wanda Bester (Heidelkor), Jan Venter (SAPPMA) and Ralph Mosikidi (Marley Pipe Systems) will join forces with appointed IFPA chairman Mike Smart (Flo-tek) in ensuring members adhere to the association’s objectives of ensuring consistently high standards of plastic pipe fabrication and installation. IFPA was formed in 2009 as an initiative by SAPPMA (the Southern African Plastic Pipe Manufacturers Association) to expand regulation of the plastic pipe industry in Southern Africa. “A well-engineered pipe system is dependent on good design, high pipe quality as well as minimum standards at the downstream end (fabricated fittings and pipeline installa-

tion). To achieve this goal, SAPPMA decided to create IFPA as a subsidiary association to attend to fabrication and installation matters,” said SAPPMA CEO Jan Venter. IFPA has established a code of conduct for its members that will ensure: • consistently high standards of plastic pipe fabrication and installation; • commitment to honest business practices and ethical standards; • support and assistance to consulting engineers and customers; • a reliable database of approved installers; • compliance with the Competition Act 89 of 1998; • compliance with all environmental laws and regulations For more info, contact 011 314 4021. www.ifpa.co.za

SAPPMA hosts 3rd annual golf day SAPPMA hosted its annual golf day at the Irene Country Club in March, the third such event the pipe industry association has hosted. 72 players taking to the field on a warm and sunny Friday morning – all happy to be out of the office and to spend a perfect summer’s day with friends and colleagues in the plastic pipe industry. “Our golf day grows in numbers, popularity and enthusiastic support each year,” said SAPPMA chairman Jan Venter. “This year we had 18 teams consisting of SAPPMA members and their clients socializing and networking with each other. These get-togethers have proven their worth in boosting industry morale and forming lasting partnerships.” The day ended with a prize-giving dinner during which prizes were awarded to the winning team, Global Plastic Welding, and runners-up Protea Polymers. Charl Fourie of Capital Polymers walked away with the longest drive prize. “We would like to thank all the players and sponsors who supported this day and look forward to another day of fun when we host the 4th SAPPMA golf day next year,” added Venter.

Winning team! – The Global Plastic Welding team, seen here with Louise Muller of SAPPMA, including Meyndert de Klerk of Global, Gary Warren (Sangio Pipe) and Craig Hanekom and Eugene Greyling of Rendifield were unbeatable on the day – well done guys!

PIPE DESIGN LECTURE

32

SAPPMA will host a full-day lecture on 18 April in Cape Town on pipe design, presented by Vollie Brink. To be held at the PlasticsSA offices in Maitland, the programme promises a varied and comprehensive overview of the topic. Under discussion will be: • Understanding engineering design • Selecting pipe materials • Risk factors and how to manage them

• What the engineer and contractor require from the pipe manufacturer • Quality assurance • Institutional requirements and green design • Building capacity for a sustainable future in design, construction, manufacturing and water efficiency. To register, email: Louise at admin@sappma.co.za

SAPPMA, DPI help keep oceans tangle-free Innovative new solution to rid oceans of used fishing line SAPPMA and one of its members, DPI Plastics, are hoping to reduce the number of marine life trapped in used and discarded fishing lines by donating plastic pipes and fittings to be used as bins by the Dyer Island Conversation Trust in a pilot project along the Gansbaai shoreline. The audited results of the annual International Ocean Clean Up initiative show revealed that 1 752 pieces of fishing line was collected along SA’s coastline. The Dyer Island Conservation Trust, in association with Overstrand Municipality, has established the Fishing Line Recovery and Recycling Program as a best practice to manage the bins. To offer a practical solution to this growing problem, SAPPMA and its members are supporting the Marine Pollution Declaration that was recently signed by Plastics/SA, by donating plastic pipes that will be used as bins where fishermen can throw away their lines. These bins are open at the top and sealed at the bottom to prevent the fishing line from being blown away. Municipality officials are responsible for opening and removing these lines on a weekly basis. The first network of 21 bins have already been erected at local beaches and popular fishing spots such as Franskraal, Gansbaai, Kleinbaai, Romansbaai, Pearly beach and Kleinmond. Another 100 bins will be made and used along the rest of the coastline. www.sappma.co.za

ASSOCIATION NEWS

South African Chemical Institute celebrates 100 years! educational issues from matriculation to university level.

New ‘eco’ organisations offer service to manufacturers

Centenary celebrations! - Ushering in the year-long celebration on 26 January was a half-day event at the School of Chemistry at Wits to which members of SACI and the South African chemical companies that support chemistry were invited. SACI members who presented a programme of humorous, informative and interesting talks on the institute’s history included Prof James Darkwa, Prof Susan Bourne, Dr Ian Brett, Prof James Bull, Prof Ivan Green, Prof Helder Marques and Prof Ernst Breet

THIS year marks the centenary of the South African Chemical Institute (SACI). Formed on 26 January 1912, the Institute was initially known as the South African Association of Analytical Chemists, and later changed its name to embrace a much larger group of chemists. Today SACI has a membership that spans the length and breadth of chemistry within and outside of South Africa’s borders. SACI has planned a series of activities to celebrate its 100 years of existence. The year-long centenary celebrations will

take the form of various symposia across South Africa. The objectives of the institute are to sustain and promote the status and integrity of chemistry and its practitioners. Throughout the years, the institute has been concerned with the status of the chemist in the eyes of the community. To look after the interests of the chemistry community, members of the Institute have served on the committees of various bodies such as the National Science and Technology Forum (NSTF) and have collaborated with other societies, discussing

Oldest chemical society in Africa As the oldest chemical society on the African continent, SACI has come a long way since its establishment in 1912. Its activities were initially limited to South Africa, but in the second half of its 100 years of existence SACI gradually extended invitations to chemists in Europe and America during its biannual conventions. Its interactions with chemists on the African continent began post-1994; it has, however, grown rapidly to the extent that SACI was one of the founding members of the recently formed Federation of African Societies of Chemistry (FASC). SACI is one of the strongest chemical societies on the continent, with its own journal – a publication which is gradually becoming the journal of choice for a number of African chemists.

www.saci.co.za

www.saci.co.za Chemist brainpower! – SACI committee members Prof James Darkwa, Prof Ivan Green, Dr Patricia Forbes, Prof Simon Lotz, Prof Neil Coville and Dr Mike Booth

Veteran knowledge – Veteran SACI member Percy Bloom, who was SACI president from 1984-86, has been involved with the institute for decades

Prof Ivan Green, Prof Neil Coville, Prof James Darkwa, Prof James Bull, Prof Ernst Breet, Mr Percy Bloom, Dr Mike Booth

Recycling a major focus at this year’s Cape Argus cycling race 82% of packaging waste generated at event recycled, up from 75% previously

Plastics SA ensures cyclists are aware of the importance of recycling their litter during the annual Cape Argus/Pick ‘n Pay Cycle Race

34

PLASTICS|SA and its intrepid team of eco-warriors encouraged the 35 000 participants in this year’s Cape Argus/Pick ‘n Pay Cycle Race to not only cycle, but also to recycle as they competed in the gruelling 105.5 km race on 11 March. According to Douw Steyn, director for sustainability for Plastics|SA and winner of the 2011 Enviropaedia Award for Recycling, the clean-up team has been responsible for collecting and recycling the waste discarded by participants during major sports events such as the Cape Argus/Pick ‘n Pay Cycle Race and the Two Oceans Marathon for the past six years. “This Waste Management Strategy, known as ‘event greening’, is about making socially and environmentally responsible decisions when organising or participating in an event. The greening of events contributes to a cleaner and greener South Africa”, Steyn explained. A team of 100 community members was appointed as the Clean-Up and Recycle team.

They received thorough training into the do’s and don’ts of recycling and covered the area between the Cape Town city centre and Sea Point. “Working with our waste management partners such as WastePlan and the City of Cape Town, we have consistently exceeded expectations of the event organisers,” Steyn said. “Instead of the anticipated 75% of total waste generated during previous year’s events, we are able to recycle an impressive 82% of the waste. This year we aimed to improve on this figure”, Steyn added. And there’s no doubt that a lot of recycling is generated: On the eve prior to the tour, a fleet of 10-ton and 5-ton trucks roll out of Coca-Cola in Cape Town’s (PenBev) Parow Industria headquarters to deliver the 55 000 litres of Coca-Cola, 60 000 litres of water and 50 000 litres of Powerade, that will keep the 35 000 cyclists hydrated throughout the Tour.

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ASSOCIATION NEWS

Eco organisations create value New ‘eco’ organisations offer service to manufacturers ADDING value is a well-known need in virtually all business relationships and now, in the relatively new territory of sustainable manufacturing practice, environmental organisations are ďŹ nding opportunities to create value. This was the focus at the ‘Hot recycling topics’ workshops presented by PETCO in Johannesburg and Cape Town in February. PETCO, which was one of the ďŹ rst material sector associations to be formed (in 2004) and which has become a standard-bearer for the many other professional groups which have sprung up in the industry over the last few years, gave a number of the new environmental/sustainable development organisations the opportunity to address delegates at the ‘Hot Recycling Topics’ workshops. The eco groups’ ‘Pecha Kucha’* style presentations were fundamentally very short presentations on what they offered. These second-tier environmental groups comprise mainly people who are active in the increasingly important sustainable development and management areas. At this stage, the choice by the individuals concerned is a bold one – as developing a ďŹ nancially viable business entity in this area is no forgone conclusion. For many manufacturers active in the mainstream plastics, composites and rubber markets, taking responsibility for the carbon footprint and other environmental impacts of their manufacturing activity can be a grudge decision. Seasoned campaigners Andrew Marthinusen of PACSA (Packaging Council of SA) and Chandru Wadwhani of Extrupet set out the scenario initially, explaining some of the realities of the market. 36

Then the focus turned to what the new ‘eco’ players are offering. ‘Social marketing’ In a presentation titled ‘Easy does it! The story of curbside recycling programmes,’ Hugh Tyrell of GreenEdge Communications outlined how his company is using proven experience in creating effective social marketing campaigns for recycling. The municipal or corporate programmes are designed to promote behaviour change, raise awareness and participation rates in ‘at-source’ community initiatives. A high level of participation by householders is required to make a voluntary programme successful. The approach used up till now – of ‘creating awareness’ or ‘educating’ people – has met with varying degrees of success, and it has become clear that simply giving people information is not sufďŹ cient to change behaviour. GreenEdge’s approach combines media and marketing communications with psychology and sociology, into what is termed ‘social marketing’. Facts about the state of the planet, decreasing natural resources and dwindling landďŹ ll space need to be communicated and understood. However, appeals to action based only on such issues can result in guilt and negative emotions, and people may avoid thinking or doing something about them as a result. So GreenEdge has been coming up with more practical scenarios where more public participation is achieved. www.greenedge.co.za

Chandru Wadwhani of Extrupet and Andrew Marthinusen of PACSA (Packaging Council of SA), relative ‘eco veterans’ of the industry, ank Cheri Scholtz of PETCO

Woolworths is using plastic bags, in some cases from recycled vinyl material, to convey important consumer and environmental messages. In this case, shoppers are informed that a donation will be made towards rhino conservation as a result of their purchase of the bag

APRIL / MAY 2012

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NOTE ‘Behaviour change’ In his presentation titled ‘Behavior change for sustainable thinking,’ Andrew Bennett of Icologie quoted some interesting historical parallels, bearing in mind that this is not the ďŹ rst time that there has been a need for humans to change their behaviour. “History teaches us that men and nations behave wisely, once they have exhausted all other alternatives,â€? was arguably one of the most relevant statements. He outlined how the next step in the process of environmental auditing, transparency, is becoming increasingly important. www.icologie.com

‘Good business journey’ Justin Smith, head of sustainability at Woolworths, outlined the six key areas the retailer has identiďŹ ed, namely: • sustainable farming • water • energy • waste • social development and • transformation. Woolworths is looking closely at the overall environmental impact of all its products. As an example of the process, Justin highlighted its life cycle assessment (LCA) of the milk sector. All impacts of the process have been

recorded, including those on water usage and carbon emissions. The organisation remains committed to the reduction in use of plastic bags, but is simultaneously making wide use of plastic packaging materials ‌ a process which has necessitated in it being committed to boosting recycling rates. Biomimicry One of the most interesting presentations was that by Will Lawson of Biomicmicry SA. Biomicmicry is the process of “learning from and then emulating nature’s genius,â€? said Will. Nature has developed many brilliant solutions to everyday problems: the most obvious being its ability to reprocess all waste materials. Examples shown by Will included incredibly strong yet light materials, how a gecko is able to attach itself on to inverted surfaces (there are several examples of this ability) The group’s mission is to nurture and grow a community of people who are learning from, emulating, and conserving life’s genius to create a healthier, more sustainable planet. Surprisingly, nature’s ingenious way of solving problems provides relevant pointers to the designers in our industry too. www.asknature.org www.biomimicrysa.co.za

* ‘Pecha Kucha Night’ was devised in Tokyo in February 2003 as an event for young designers to meet, network and show their work in public. Drawing its name from the Japanese term for ‘chit chat’, the events involve a rotation of concise presentations based on a simple idea: 20 images x 20 seconds. The result is a series of concise presentations and keeps things moving at a rapid pace. The format has since become popular worldwide. www.petco.co.za

TrashBack In another example of creating opportunities which previously did not apparently exist, TrashBack, a new social enterprise, is incentivising disadvantaged communities to manage their own waste and recycle. What happens when you turn trash into treasure? www.trashback.org

Congratulations are due to the PETCO team for, ďŹ rstly, locating these new ‘eco’ organisations and then giving them the opportunity to present their plans. At least some of the manufacturers in the industry will be happy to work with such organisations as they develop their environmental and energy-saving programmes.

Environmental auditing now forms an important part of the overall process of corporate responsibility

One of the print adverts developed by GreenEdge which are based on ‘social marketing’ APRIL / MAY 2012 37

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ASSOCIATION NEWS

Berg2Beach campaign Plastics|SA launches campaign during Water Week 2012 PLASTICS|SA used National Water Week (18-23 March) as a platform to launch one of the Sustainability Council’s Waste Management Strategies for 2012. “Our Clean Up and Recycle theme for 2012 is ‘Berg2Beach’ and we want to encourage all South Africans to help keep the country clean, from the mountains to the oceans,� said Douw Steyn, Director: Sustainability at Plastics|SA and winner of the 2011 Enviropaedia Award for Recycling. This is the 16th year that Plastics|SA has supported Cleanup SA and Water Week. Eco-Care Trust, WESSA, KZN Wildlife and Canoe SA are some of the non-governmental organizations concerned with the conservation of South Africa’s natural water resources and ecosystems which enjoys the support of Plastics|SA. “Plastics|SA is proud to support these organisations by supplying the Cleanup volunteers with cleanup bags and supporting their cleanup campaigns,� said Steyn. Other initiatives which Plastics|SA supports include regular clean-ups of the Jukskei River in Gauteng and the ‘Friends 38

of the Liesbeeck’ in Cape Town and the Umgeni River together with the KZN Wildlife. Plastics/SA has sponsored two boats which are being used for the cleaning of the Liesbeeck River in Cape Town and the Durban Mangroves at the Umgeni River mouth. Plastics|SA will also be supporting and sponsoring Nikita van der Merwe, a 12-yearold, Grade 7 pupil at Gert Maritz Primary School in Pietermaritzburg, who will be embarking on a canoe expedition in order to raise awareness of water pollution and the negative impact it has on the KZN’s rivers and dams. She has already completed canoeing the Midmar Dam as the ďŹ rst stage of her efforts and will be canoeing all the dams that fall within Ezemvelo KZN Wildlife, after which she will be earmarking other dams in KwaZulu-Natal. Finally, Plastics|SA will also be harnessing the power of the internet via its website and its Facebook page from 24 March until 25 September as part of the worldwide ‘Let’s Do It!’ movement. More than 80 countries will be brought together in this World Cleanup 2012 action, aimed at activating a global

A view of a litter trap made out of 146 plastic bottles, shade netting and rope in the Liesbeeck River

network of civic leaders, scientists and experts to gather the most efďŹ cient and sustainable solutions for waste management and recycling. www.cleanup-SA.co.za

APRIL / MAY 2012

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Fire in focus Industry has done much to improve fire performance of polymers, PISA Northern branch conference hears the topic, ‘Fire Safety of Plastic Materials,’ at the Bytes conference centre in Midrand on 21 February. The locals’ casual attitude towards fire risk was almost immediately noted by Most of us will probably answer ‘no’ to both some of the global guest speakers, who rethese questions, which is not a satisfactory marked that such conferences internationally situation – and probably highly unsatisfacusually started with an explanation of what to tory if a fire originates in your home or even do in the event of a fire. In other words, and of nearby. Fire is a topic which people generally most immediate importance: what evacuation prefer to avoid and, unless you’ve witnessed procedures to follow. People in Africa presuma fire or seen the ably rely on speed off results, it’s a case of the mark to escape the Focus of measures to ‘out of sight is out of zone, but in many cases reduce flammability risk mind’. But it’s a very that’s not enough. of polymer materials is real problem, and According to to delay the process to plastics materials have David Poxon, general over the years been manager of the Fire Proincrease escape time blamed for some of the tection Association of SA, the risk of fire in South Africa is not to be most hazardous fires. Don’t panic, however, underestimated. FPASA’s records show that big fires have been going on for a long time, for the most recently monitored period, 2009, for hundreds of years actually – even in the losses due to fire around the country were 1600s, some of Europe’s big cities were hit estimated at R2,013-billion. That equates by massive conflagrations. More recently, PISA’s Northern branch took to R167-million a month – averaging out at about R229,000 an hour. These figures are the bold step of organising a conference on

DO YOU have a fire extinguisher in your home? Or know where the nearest fire extinguisher is?

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APRIL / MAY 2012

probably conservative as many fires are not fully reported, said Poxon, who is one of SA’s top experts on fire. A large percentage of the cases occur in the domestic environment (about 8603 cases in 2009) and transport areas (2583 cases that year) and in many of the instances polymer materials have also ignited. There are an estimated 39 fire brigades around the country, apart from the fire fighting equipment used by municipalities, and in 2009 they were called out on a whopping 40 481 fire emergencies. In about a quarter of the cases, the cause of the fire is (and remains) undetermined, which has resulted in Poxon being of the view that fire risk procedure is not being well managed in South Africa. In many of the cases, proper design procedures may have not been followed. In fact, in one of the worst

Testing time – There’s little one can do once a ďŹ re really gets going, but important observations can be drawn from monitoring the process. Fire testing is literally the business of Firelab of Pretoria. The company’s Karel van Dyk showed how combustibility testing of building materials at up to 750ÂşC and higher is conducted. This is obviously a serious undertaking, and Firelab has been able to make some very relevant recommendations. • Firelab can be reached on phone 012 349 2929.

ďŹ res in the industry itself, the 1996 blaze in which a plastics factory in Johannesburg was razed, construction of the plant had deviated from the original plans. There have been a number of other ďŹ res in the industry itself over the last few years, including ďŹ res at a polystyrene foam manufacturing business (source material styrene is exceptionally ammable), an injection moulding business, a ďŹ lm printing business (solvents used in printing are hazardous) and others. www.fpasa.co.za

Source of much blame Prior to the development of more effective ďŹ re retardant (FR) additives, fumes from the burning of plastic materials were widely

blamed for the death of victims, mainly as a result of noxious gases emitted. Foams used in furniture cushioning and insulation in work and domestic situations and cable insulation in mines and transport areas were seen as major culprits. As the conference progressed, however, it became apparent that not only have FR systems become far more effective, but that a huge quantity of research has been focused on the area too. The research has led to the development of standards for ďŹ re prevention materials and measures, which topic formed a main component of the conference. The standards process has focused particularly on expanded polystyrene, PVC and polyurethanes, which materials have up till now been most likely

to appear in expanded foam form. But, as always, there has not been complete agreement with standards setting process. The simple fact of the matter is that in the amount of combustible materials is greater in the more industrialised nations, a situation which has almost unexpectedly presented an opportunity for developing nations to learn from the international experience. South Africa ďŹ ts into the latter category and the event hence provided an opportunity for SA suppliers to gain from the international speakers present. Since elimination of the risk of ďŹ re is basically impossible, the focus of measures to reduce the ammability risk of polymer materials is rather to delay the process APRIL / MAY 2012 41

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ASSOCIATION NEWS 1

1. Fired up! Erich Seeger of the SABS is anked by visiting international speakers Stephen Grayson of Fire Testing Technology (FTT) of the UK and Kasturirangan Kannah of Great Lakes, based in Germany

2

2. David Poxon, general manager of the Fire Protection Association of SA, gave an interesting presentation about the frequency of ďŹ res in the country. Every ďŹ re is different said, so it’s not always easy to draw clear conclusions

to increase escape time ‌ and allow for manual intervention. Effective FR systems can increase the escape time from two to as much as 20 minutes. FRs operate by a variety of means, charring being just one, which create the delay allowing for escape. Complexity of the problem The presenter of the industry keynote address, Dr Juergen Troitzsch of Fire and Environment Protection Service of Germany, was unfortunately unable to attend due to, of all things, a skiing accident. Troitzsch was 42

4

3. Stephen Grayson of Fire Testing Technology (FTT) of the UK on is company’s exhibition stand

to have given an address on ‘Global Trends in Fire Safety and Standards in Plastics,’ which would have been interesting. Kasturirangan Kannah of Great Lakes then gave an address on ‘Flame Retardants in Plastics: Regulatory and Environmental Challenges’. At once the complexity of the topic became clear. Achieving an effective FR solution is an illusive target, due partly to the complexity of materials in use as well as

APRIL / MAY 2012

CHEMFIT INNOVATIVE SOLUTIONS IN POLYMER ADDITIVES

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4. Michael Kearns of Great Lakes Solutions with Tania Postlethwaite of ChemďŹ t, the global group’s SA agent. Great Lakes was one of the exhibitors at the ďŹ re conference

the wide variety of applications of moulded products. Kannah pointed out that FR additives are produced from a variety of natural products, including nitrogen, aluminum, chloride, magnesium, phosphorus and bromide. Finding the correct balance for any speciďŹ c application is hence complicated. He outlined various examples – including enclosures, printed circuit boards, cables and connectors – and the varied solutions reached. The audience at once began to absorb the complexity of the problem. Slowing down combustion creates the opportunity to maintain a viable atmosphere, said Kannah. The man factors for plastic product manufactures include: • efďŹ cacy of ame retardants in chosen polymer system; • cost vs beneďŹ ts of feasible alternatives; • environmental considerations. Of these, cost is obviously an important consideration, but cost of litigation due to failure of products you’ve supplied could on the other hand be highly damaging. Great Solutions Kannah’s colleague at Great Lakes group, Michael Kearns, then entertained delegates with a lively presentation titled ‘Greener Innovation: An Update on Great Lakes Solutions’ Flame Retardants’. Founded in 1933 in Michigan, USA, Great Lakes is arguably the world leader in FRs for polymers. Its purchases of bromine-rich wells in Arkansas as well as a phosphorus source have clearly given it a competitive advantage in the area. Great Lakes actually changed its name in 2005 to Chemtura, after it merged with another additive supplier, Crompton, but then returned to its source name as Great Lakes Solutions in 2010 to ‘fully brand what it is’. As the name suggests, the business is literally focused on solutions. Great Lakes’ produces the Emerald™ range for FRs and has solutions, well, for virtually every polymer material, from polyamides and polycarbonates to unsaturated polyesters, styrenics and epoxies. www.greatlakes.com

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GLOBAL INTERGRATION

LOCAL INNOVATION

10. Piet Makhubela of Sasol, Sipho Khumalo of Aberdare Cables, Anton Hanekom of PlasticsSA and Vincent Khumalo of CSIR

5

5. Debbie Beaton of Plastichem and Annabé Pretorius of Plastix 911 were among the guests

6

7

6. Organisers – Tim Cooper, who has recently started the company Addivation, and Horst Seute of Global Extrusion Services led with PISA Northern branch team which organised the conference … in fact, they did just about everything! Well done guys

7. Pixley Makhubo, PISA Northern chairman, is flanked by George Thorburn and Brian Bowman of Plastic Bubbles

‘Predicting the Fire Performance of Products from Bench Scale Fire Tests’. Significant experience in the area is obviously necessary here, since extrapolating bench-scale results to those of a material’s performance in a major fire situation is not necessarily obvious. Grayson, however, is something of a doyen of the international fire testing area, and one who’s happy to engage in debate on the topic. He followed that up with a second paper, a ‘Review of Developments in European Fire Test and Classification for Construction Products, Electric Cables and Railways’. Although the process is mainly empirical, it can www.fire-testing.com also deteriorate: one example being a clash between the French and Germans, where the former have resisted acceptance of proposed Predicting fire performance standards as they simply don’t want German Stephen Grayson of Fire Testing Technology (FTT) of the UK then gave a presentation titled train coaches in France. SA situation Erich Seeger, manager of the Civil and Mechanical Laboratories at the SABS then gave a presentation about the local standards bureau’s ‘Testing and Certification’ process. Not unsurprisingly, this is also a complex process, not least bedeviled by the difficulty of enforcing standards adhesion. According to Seeger, it’s difficult to prevent illegal use of the SABS standards symbol by manufacturers. Are they going to send the police around? Complaints from rival manufacturers appears to be only factor leading up to possible cessation of illegal use.

8

8. PISA national chairman Alain Berichon opened the conference in style

9

9. Keith Anderson, chairman of eWaste Association of South Africa, gave a presentation on ‘The Good, the Bad and the Ugly of the SA eWaste Scenario’

Composites Steve Woodhall of Scott Bader kept the composites’ flag flying with a presentation on ‘Fire Retardants and Composite Materials,’ a joint work with Dr Les Norwood of Scott Bader UK. He outlined how smoke and toxic fume generation have driven resin development towards reduced toxicity and halogenfree materials (halogens release corrosive acid fumes that damage structures and make people ill). However, thermosetting resins are inherently heat stable and do not melt to form burning droplets, said Steve. Intumescent coatings (which swell as a result of heat exposure, thus increasing in volume, while decreasing in density) can create an important protective layer, protecting the laminate from fire. www.scottbader.co.za

Plastics Institute of Southern Africa National Chairman Alain Berichon p. 031 461 2990 c. 082 888 2429 e. alain@neupack.co.za National Vice-Chairman Martin Wells p. 021 712 1408 c. 082 822 8115 e. martin@summitpub.co.za National Secretary David Rule p. 011 452 6940 c. 082 552 0726 e. david@plasticolors.co.za

KwaZulu-Natal Garth Taylor c. 084 924 4551 e. garth@pcasa.co.za Northern Pixley Makhubo p. 011 458 0719 c. 083 628 5215 e. pixley.makhubo@sasol.com Western Cape Billy MacMillan c. 082 453 7070 e. billy@superthene.com www.pisa.org.za

Most widely used flame retardants types: Flame retardants work by one of three mechanisms, 1) interruption of radical mechanism of combustion process in the gas phase; 2) reaction in the solid phase to form a carbonaceous char which serves as a barrier between fuel and the heat and oxygen source; 3) endothermic processes, such as release of water, to remove the heat from the reaction SOURCE: GREAT LAKES SOLUTIONS

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11. Panel – The organisers of the event are to be congratulated for coordinating a high-level group of speakers for the fire seminar

12

12. Relaxing afterwards; Steve Woodhall of Scott Bader flanked by Hein Landsburg and Ryan Harrison of Chemfit, who were the main sponsors together with their principal Great Lakes Solutions 43

ASSOCIATION NEWS

Tests show inclusion of ‘oxo’ additive has little effect on recycled material Research programme focused on comparison of materials containing oxo-biodegradable additive or without THE recycling of material containing oxobiodegradable additives has almost no effect on subsequently moulded products, according to research by Roediger Agencies of Stellenbosh. One of the most disputed topics in the industry in recent times, the use of oxobiodegradable additives in plastic products and specifically the effect the additive could have on products made from recycled material containing it was addressed at a PISA lecture by Dr Andy Roediger in Cape Town in February. Dr Roediger, who runs an analytical lab at Stellenbosch, gave an address titled ‘Recyclability of Plastics Containing Oxobiodegradable Additives – Facts & Figures’. The introduction of oxo-biodegradable additives into plastic products, specifically packaging items was initially seen as a good solution for plastic items ending up in the environment, allowing them to degrade automatically and disappear. One of the problem areas was the perceived difficulty the oxo-additives may have created for recyclers. It was suspected that products made from recycled material containing the additive could subsequently auto-degrade too. Roediger conducted a series of tests focussed on the performance of products moulded with recycled material containing the additive in various percentages. The main factors behind the performance of oxo additives include: • the fact that transition metal compounds accelerate polymer breakdown; • polymers break down in the presence of oxygen with heat and/or UV light; • the process can be prevented/slowed down by the addition of antioxidants. In the research programme, biodegradable additive was compounded into virgin LDPE and the compound was used as a source of biodegradable polymer. Pellets produced from recycled printed film were purchased from a recycler and, together with the material containing the biodegradable additive, taken to a film blower where the two were blended in various rations, from 100% oxobiodegradable (OBD) to a 50:50 ratio of OBD:recycled printed film. The various material rations were then subjected to accelerated aging tests, involving exposure to UV light and heat of 60ºC. Tensile strength and strain break tests of 44

APRIL / MAY 2012

Dr Andy Roediger presented findings of research into the performance of material containing oxo-biodegradable additive after recycling

the various materials, of both oven-aged and QUV samples, showed up only very slight differences in performance. Extrusion tests In the extrusion test results then presented, film containing the biodegradable additive was pelletised and blended with pellets of recycled LLDPE purchased from a recycler, from which new compound was produced. Five sets of tests were performed again, starting from 100% of the material contain-

ing OBD to various ratios of the OBD and reprocessed LLDPE materials. The blended materials included 2% of masterbatch. Observations following testing closely mirrored the blown film results, in fact, the UV tests showed there was practically no difference in tensile strength loss after two years.

www.roedigeragencies.co.za

Table 1: BLOWN FILM SUMMARY HEAT TESTS • No difference in tensile strength loss after 6.7 months • No difference in elongation loss after 3.3 months • Some difference in elongation loss after 5 months UV TESTS • No difference in tensile strength loss after 1.4 years • No difference in elongation loss after 6.7 months Extrusion tests: Material made with film containing ‘d2w’ was compared with material produced from recycled LLDPE without the additive, and then of material containing various percentages of material with ‘d2w’, showed very little difference in performance

THE POLYMER SOLUTIONS COMPANY Plastamid, a member of the Chemical Services Group, has brought premier polymer solutions, extensive application development and technical service to the local and international polymer markets for over 35 years. Plastamid plays a leading role in the manufacture and supply of thermoplastic compounds to a diverse range of industries.

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ASSOCIATION NEWS Plastics Convertors Association

Deadlock between industry, MEIBC remains unresolved THE situation surrounding the plastics industry’s attempts to withdraw from the MEIBC (Metal & Engineering Bargaining Council) was discussed at meetings convened by the PCA Gerhard Papenfus of around the country NEASA was the guest in March. speaker at the PCA events around the Gerhard Papcountry in March enfus, director of NEASA (National Employers Association of SA) was the guest speaker, updated delegates about the current situation, specifically about NEASA’s urgent application in the Labour Court. The fact of the matter is that the scenario is not as simple as originally anticipated, and few PCA members or other businessmen in the industry fully comprehend what the problems are. In short, the MEIBC appears to be extremely reluctant for the industry to withdraw and established its

Executive Director Johan Pieterse p. 011 314 0019 c. 082 904 8274 johan@pcasa.co.za Regional Manager (KZN/E Cape) Garth Taylor c. 084 924 4551 garth@pcasa.co.za Western Cape Andy van Tonder c. 084 543 1430 andy@pcasa.co.za Executive Officer Mike Bullock c. 082 888 9686 mikeb@pcsa.co.za

Members of the plastic fraternity who attended the PCA event in Midrand included Johan Nel of PWD Plastics, Farai Mapenzauswa of Miller Methods, Xikombiso Shibambu of Ampaglas, Francois Booysens of SA Plastikor and Sizakele Mahlutshana of Crystal Pack

own bargaining structure, for reasons that few comprehend. The NEASA director looked at the demographics in which the industry and indeed the current bargaining authority find themselves in and what a suitable outcome for both would be. Following that, attendees were also briefed on the latest vest-type carrier bags legislation. In terms of the National Regulator for Compulsory Specifications’ (NRCS) regulations, only the company reference number will need

www.pcasa.co.za

to be printed on the bags. Details of the manufacturer, country and year of manufacture and ink requirements can be removed. Printing tests are no longer necessary, and the bag wall thickness is to remain at 30μ. All this will result in a significant cost saving. The proposed changes are before the NRCS board and, if approved, will be published asking for comment within 60 days. If the process goes according plan the amended regulations will be effective in early 2013.

Changes to Labour, Conditions of Employment Acts to be explained THE PCA is conducting a series of training seminars around the country in May at which the implications of the changes to the Labour Relations Act as well as the Basic Conditions of Employment Act will be fully explained. The seminars are designed to

assist members to fully understand the process and hence to manage such effectively. Topics to be addressed include the • amendments to the powers of the Labour Court; • amendments to the right to strike and recourse to lockout;

• amendments to the meaning of dismissal, and much more. In fact, the proposed changes to the Labour Relations Act are so substantial that employers cannot afford to not be at the seminar. www.pcasa.co.za

East Capers combine AGM with food, wine ‘tour’ THE Eastern Cape branch of the Institute of Materials held its AGM on 28 February, following which members and guests were treated to a thoroughly enjoyable wine tasting. Presented by Linus Serfontein, the event took the form of an entertaining and educational food and wine pairing. This is the second time Linus has presented a wine tasting to the EC branch, and we strongly suspect that it won’t be the last! Linus has many years of experience in wine appreciation and his broad knowledge of wine from all over world and his enthusiasm to share this is earning him quite a name in Port Elizabeth. The basic food tastes, viz. sweet, sour, bitter and salty, were sampled with five different wines, in order to test which worked and which didn’t… and there were defi-

nitely some surprises! Linus also included a cheese, to highlight the creamy component of some foods and how various types of wines and foods can bring out certain flavours in each other. The wines showcased this time round were the less common cultivars of Viognier and Mourvedre, which are originally from vineyards in Southern France and are often present in blends with Shiraz, such as SMV. These were Excelsior Viognier from the Robertson area, Table Bay Shiraz, Mad Hatter’s Mourvedre from Wellington and Boekenhoutskloof ‘Wolftrap”, which is an SMV blend containing 65% Shiraz, 32% Mourvedre and 3% Viognier. There was also a white Muskadel from Oranjerivier to throw some sweetness into the mix.

Oh yes, and the committee: Deon Riekert and Christie Olivier have stepped down after a good few years of service, and the committee for 2012 will be chaired by Coen Burger, along with Tertius de Ridder, Diane van Rooyen, Kathy Garde and Fourene Smith. Portfolios will be decided at the first meeting of the new committee. Institute of Materials: Southern Africa Region National Chairman Hans Strydom p. 011 425 3241 c. 082 449 5920 hans@rubbernano.co.za

KwaZulu-Natal André Cornelius c. 071 682 9885 andre.cornelius@ karbochem.co.za

Eastern Cape Coen Burger c. 082 456 6656 coenburger@axxess.co.za

Northern Spike Taylor p. 011 928 4172 c. 082 456 5734 spiket@multotec.co.za

Secretary Diane van Rooyen p. 041 486 1505 diane@snrubber.co.za

www.iom3.org

46

APRIL / MAY 2012 www.iom3.co.za

Tight fight at Cape golf day THE PISA Western Cape golf day was again a tight fight, but all were calm once hostilities ceased. The event took place for the first time at the Durbanville course, which was in excellent nick … a situation which didn’t necessarily make life easier for the occasional golfers. Full marks again to our regular golfers, who year after year handle the pressure of scoring. If the results are anything to go by, however, the ‘formula’ appears to be working: three teams scored over 90 points and a large group were in the high 80s. So well done to all. Specials thanks are due to our main sponsor, Plastomark. Plans are afoot to get Ronnie Sloan of Plastomark to actually play next year! Our other sponsors included Agriplas, Alplas, Colour Systems, Maritime Marketing, Masterbatch SA, Plasquip, Polyoak, Progetto, Specialised Plastic Industries, Summit Publishing, Usabco, West African Group and JourneysEnd Wines.

Plastics Convertors Association of South Africa TRAINING SEMINAR DURING THE MONTH OF MAY 2012 LABOUR RELATIONS & BASIC CONDITIONS OF EMPLOYMENT AMENDMENT BILL As per our commitment during our preparations in making submissions on the proposed amendments to the LRA & BCEA, we will be hosting training seminars to discuss and explain the amendments as well as the effect of same on employers.

1

WHO SHOULD ATTEND? All HR & IR Managers, Directors / Managers, Staff dealing with unions and normal Industrial Relations. WHY SHOULD MEMBERS ATTEND? 2

The seminar is designed to assist members to fully understand the implications the changes to the Labour Relations Act as well as the Basic Conditions of Employment Act will bring about, and to manage such effectively. WHEN / WHERE WILL THE SEMINARS TAKE PLACE?

3

Gauteng: May 14th & 15th 2012 Plastics SA Midrand

4

KwaZulu Natal: May 16th 2012 Durban Country Club Western Cape: May 17th 2012 Kelvin Grove COST PER DELEGATE: 1. Winners – With a whopping 94 points, the fourball comprising Alan Caldwell, Dale Smith, Craig Childs and David Barnard held off challengers on the day 2. Team SPI – Hot on their heels were Stan Langenhoven jnr and snr, Danie Maritz of Specialised Plastics Industries and Gareth Williams 3. Big hitter! – Gary Crawford of Aquamark Manufacturing took the longest drive prize again 4. Lucky draw – Phil Johnson of Masterbatch SA, with Claire Gibson of PISA Western Cape committee, won the lucky draw prize, a hopper-loader from Plasquip APRIL / MAY 2012

47

ü ü ü ü

R 1250 00 (Excl. VAT) for first member delegate and R 750 (Excl VAT) for additional member delegates. Non Members R 2 500.00 (Excl VAT) per delegate. The above includes course material, legislation and catering / refreshments Limited seating available so book early to avoid disappointment.

HOW TO BOOK YOUR PLACE: Carol Klomfass | E: carol@pcasa.co.za T: (011) 314 0019 | F: (011) 314 3765 / 086 685 6350

ASSOCIATION NEWS

New board and direction for PSPC Post-consumer polystyrene recycling remains key area of focus ers and representatives from Plastics|SA, THE Polystyrene EPSASA (Expanded Polystyrene AssociaPackaging Council tion dealing with building products), retailers, (PSPC) has a new board and strategic waste management companies and recyclers amongst its members. direction that will “We will continue to build our partnerships drive the Council’s and networks with other relevant industry activities for the associations, both locally and overseas, as coming year. New office bear- we support and initiate projects that grow the industry, whilst ensuring effective recyers for the PSPC cling activities in South Africa,” Orlepp said. are Ivan Ortlepp of Ivan Ortlepp of CibaPac, CibaPac (chairthe Polystyrene Collection and recycling a key focus man), Rowan le Packaging Council’s Finding ways to effectively collect and Roux of Polynew chairman recycle contaminated post-consumer oak Packaging polystyrene will continue to be one of the (vice-chairman) and Ken Morris of MPact PSPC’s key areas of focus during the next (finances). The technical members of the few years. With more than 50 000 tons of PSPC are Elana de Goede, supported expanded and high impact polystyrene by committee members Brent Hean, Ian being converted in Edwards, Anton MainCurrently, approximately South Africa annually gaard, Neale Gordon. for the food packaging Adri Spangenberg 11% of used polystyrene and building industry, remains a director. is being recycled in South the PSPC views it as The PSPC was origiAfrica and used for the being vitally important nally formed in 2007 manufacture of photo to increase its footprint by a group involving of polystyrene colWerner Rettenbacher frames, seedling trays, lections around the of BASF, Brent Hean clothing hangars and country and improve of Metmar and Greg stationery. recycling efforts Metcalf of Plastform once the polystyrene food containers and (who was also the council’s first chairman), packaging material have left the hands of with the aim of setting in place the necesthe consumer. sary resources and mechanisms to deal Currently, approximately 11% of used with projects that enhance the reputation of polystyrene is being recycled in South Africa polystyrene packaging. and used for the manufacture of photo “Today, five years later, we are proud frames, seedling trays, clothing hangars and to announce that the PSPC has grown to represent more than 80% of the polystyrene stationery. “We have exciting plans on the table that food packaging market,” said new chairwill revolutionize the polystyrene recycling man, Ivan Ortlepp. industry and increase both the value and the The council is proud to count polymer demand for used polystyrene in our country. suppliers, polystyrene packaging convert48

APRIL / MAY 2012

Contact: Derick Labuschagne Tel: 011 979 2766 Fax: 011 979 2424 Email: annecatsales@mweb.co.za www.annecat.co.za

However, we will continue to support the local plastic industry’s call for separation at source to ensure cleaner, less contaminated materials from the domestic waste stream and to develop new markets for recycled materials, as plastics recycling is driven by demand,” Ortlepp said. Other objectives of the PSPC will be: • to educate, communicate and support activities that improve the industry in a generic manner • to address key public concerns related to the use of PS and EPS by using a science-based decision making process that forms part of our commitment to Responsible Care. • to improve cooperation between the Council and leading retailers “Polystyrene has a considerable contribution to make to the life of the consumer, be it in the form of fast food packaging, protective packaging or in the form of rigid packaging. As an industry, we contribute significantly to job creation, economic growth, employment and convenient living without sacrificing our environmental responsibilities and obligations. We look forward to a highlight year in the history of the South African Polystyrene industry”, Ortlepp added. • ADRI SPANGENBERG CAN BE CONTACTED ON (012) 259-0554, CELL (082) 686-5082 OR EMAIL: ADRI@POLYSTYRENEPACKAGING. CO.ZA

www.polystyrenepackaging.co.za

WELL DONE!

Representatives of new recipients of the projects wheelchairs included Linda Walters for Connect, Jackie de la Porte for Vista Nova Primary School, Debbie Gonzales for Ocean View Person for Disabilities, Herman van Wyk for Pollsmoor Correctional Services, and Dolores Needham for Seventh Heaven. In front are Breadtags for Wheelchairs Project founder, Mary Honeybun, and Polystyrene Packaging Council CEO Adri Spangenberg

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Record year for

breadtags THANKS to hundreds of volunteers around the country who collected thousands of breadtags, the Polystyrene Packaging Council (PSPC) has donated 207 wheelchairs as part of the Breadtags for Wheelchairs project it manages and administers Currently in its fourth year, the project encourages people around the country to collect breadtags (made from HDPP), which are then sold on to a recycler and the money raised used to buy wheelchairs for people who are unable to afford them. At a special function organised by the PSPC in Cape Town in March to thank volunteers and to hand over more wheelchairs, founder of the Breadtags for Wheelchairs Project, Mary Honeybun, said that over 1000 kg of breadtags have already been collected countrywide this year, and an estimated 5 000kg were collected in 2011. www.polystyrenepackaging.co.za

APRIL / MAY 2012

49

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Cyclelink Hestico’s Gavin Kilpatrick, a Beijing Para Olympic bronze medalist who suffers from retinitis pigmentosa, with Clint Cosgrave on the podium after winning the Disabled Tandem event at the Ride for Sight race

Cyclelink Hestico riders at the recent Ride For Sight event, including Gavin Kilpatrick, Johnny Fourie, Dominique Mouton, Kelvin Mills, Jared Gemmell, Vickers Brits and Clint Cosgrave

PEOPLE

Hestico major sponsor of cycling club THE Cycle Link cycling club welcomed two new major sponsors this year, Hestico and Yudo, a process which also led to the renaming the club to Cyclelink Hestico. With 35 members and growing fast, the club supports and encourages disabled athletes to join and participate in cycling. One of their leading cyclists, Gavin Kilpatrick, who suffers from retinitis pigmentosa*, is a Beijing Para Olympic bronze medalist who will also be competing in the

Olympic Games in London this year in various rowing events. Gavin and partner Clint Cosgrave competed in the tandem event in the recent the ‘Ride for Sight’ 116km race, winning the disabled category in a very respectable 2 hours 57 minutes and coming 21st overall. Ride for Sight is a fundraising event to raise funds for Retina SA, which carries out research to find a cure for retinitis pigmentosa. Retina SA is also one of

the club’s sponsors and thus also one of the club’s main causes. Other sponsors include GEM Real Estate, Manuton Computer Care and Bausch+Lomb. Cyclelink Hestica did very well in the recent Carnival City 65km race with four of their riders finishing in the top 16. Jared Gemmell came second, Kelvin Mills eighth, Dominique Mouton 15th and Johnny Fourie rolled in next in 16th place. Well done to all of them!

(* This is an eye disease which causes damage to the retina.)

L i ans u management team vi s i t S A

ON THE MOVE Freddie Scherer, previously of Swift Plastics in Cape Town, is now retired and living happily somewhere in the mountains in Switzerland. In the European winter he does, however, venture south. He recently spent several months in Cape Town. Harry Erasmus retired as MD of Plastic Packaging Namibia, in Windhoek, at the end of December and is now farming full-time. He remains a shareholder and director of PPNam, however; Jaco Venter has taken over as MD of the Windhoek-based film extrusion and bag-making business. The Plastic Packaging Namibia group includes Namibia Polymer Recyclers, also in Windhoek, Plastic Packaging Cape in Upington and Ango Plasticos in Angola.

50

APRIL / MAY 2012

A DELEGATION of Liansu Machinery Manufacturing Company’s top brass recently visited South Africa to strengthen ties with their customer base, and meet with agent Cabletech Marketing, responsible for sales and service both in the South African local and African markets. The Liansu group was founded in 1986 and can best be described as the behemoth of the extrusion market in China, possibly the world. A visit to the Liansu factories is an education in scale. The manufacturer’s factories are best viewed from the back of a golf cart, and still Liansu is growing. Touring these factories on foot is reserved for only the super fit. Liansu manufacture pipe, profile, electrical conduit and fittings on in-house manufactured machinery with the help of 20 000 employees in 16 factories covering a staggering 3.4 million square metres of manufacturing space. The 30 000 tons PVC piping and 5 000

tons PE piping are manufactured on 500 Liansu extrusion lines while the 1000 injection moulding machines churn out the fittings to suit. The material used in the Liansu factories each month is roughly three times more than the entire South African pipe manufacturing industry usage combined. Liansu recently added Junjia Machinery Manufacturing Company, a supplier of complete cast film extrusion lines and the first Chinese machine manufacturer to add and offer 7-layer cast film extrusion lines to the industry. Also acquired was Wanjia Plastics Corporation, sister company to Junjia Machinery Manufacturing Company, responsible for the manufacturing of cast film. • CABLETECH MARKETING REPRESENT LIANSU SALES AND SERVICE.

www.cabletech.co.za

Wesley Wu (Overseas Sales – Africa), Irene Liao (Sales Manager), Daneil Steenkamp (Liansu Product Manager Cabletech Marketing), Wei Guang Zhang (General Manager Liansu), Pierre Jurgens (Managing Director Cabletech Marketing) and Yin Zhaocheng (Manufacturing Manager, Liansu)

JOIN THE EXTRUSION JUGGERNAUT x

PIPE EXTRUSION

x

PROFILE EXTRUSION

x

SHEET EXTRUSION

x

CAST FILM EXTRUSION

x

PIPE FITTING INJECTION MOULDS

FOR FURTHER INFORMATION CONTACT: DANEIL STEENKAMP:

082 495 2964

ANDY WOODS:

082 957 9324

PIERRE JURGENS:

083 276 1978

TEL: +27 (0) 11 7040824

Fax: +27 (0) 11 462 2108 EMAIL: info@cabletech.co.za WEBSITE: www.cabletech.co.za

Triple8’s Martin floors it in restored ’61 DKW in Welkom, where he came JOHN Martin of Triple 8 Equipaway with an almost identiment Supplies of Durban has cal set of results. recently become involved in hisGiven that the ‘Deek’ toric car racing, quite seriously is the only one of its kind involved in fact. He acquired a racing in South Africa at the 1961 DKW ‘Junior’ almost two moment, a lot of attention years ago and has slowly been has been given to John restoring the vintage vehicle to and his car by both fellow its former glory. competitors and the public Given that this same marque alike. John, who is also a was the legendary Sarel ‘Supermember of the PISA KZN van’ van der Merwe’s first ever committee, admits to feelrace car, John has gone about ing quite like a celebrity: turning it into a replica of Sarel’s Fast cornering – John Martin of Triple8 Equipment Supplies of Durban has, ‘Supervan’-like, taken the chequered flag at a number of vintage vehicle races he’s been interviewed by multiple race-winning model in his restored 1961 DKW ‘Rapid Motion Classic’ for – he’s even got the vehicle’s DSTV’s ‘Supersport’ chanroof autographed by the legend where he finished third overall after a nel. He’s living out a life-long dream of being himself. The DKW – or ‘Deek’ as it’s known – number of heats. The Deek actually took the able to race and we wish him many years of was put to the test earlier this year when John chequered flag in the second heat! In Februwins ahead. travelled to Zwartkops in Pretoria in January, ary the action shifted to the Phakisa raceway

PEOPLE

Plastics industry recruitment a global affair LISTGROVE Limited, a leading international recruitment and human resources company specializing in the plastics industry since 1975, is taking part in the forthcoming NPE exhibition from 1-5 April. Ryan Kirby, director of international projects for Listgrove, will be present at the company stand. Listgrove will showcase its expertise in servicing the most complex and demanding recruitment briefs for international businesses that produce polymers, packaging and associated products. They provide a range of services including; search, selec-

tion, database search, advertising support, market research, outplacement and career transition, interim placement and psychometric testing. Listgrove’s position as a long established and successful human resource consultancy is supported by its membership of the British Plastic Federation’s business ‘support network’, where they have been selected to offer guidance to other members concerning all HR and recruitment matters. In addition, Listgrove provide the same service to the British Packaging Federation’s member companies. Listgrove has also recently established an office in Bahrain to support the increasing demand for their services in EMEA territories. Recently the company has been engaged by several recognized plastics and packaging businesses in North America to

support recruitment projects in the USA and also to source additional staff across Europe, Asia, the Middle East and Africa. Listgrove has been selected onto PSL’s with clients such as DSM, ITW, Sabic, Lyondell Basell, Eastman Chemicals, Honeywell, Philips, Teknor Apex, Thermofisher, Smithers Rapra and Colormatrix (Polyone) primarily to support their business growth and development outside of the USA. In addition, they recently completed a number of retained assignments in the USA to appoint American nationals into General Management, Project Management, Sales Management and Manufacturing Management positions, along with a wide range of Engineering Specialists and Shop Floor roles. www.listgrove.com

New face at Zanogen

Farewell to Gold Pack Awards custodian

ZANOGEN Machine Knives recently welcomed Steven Leukes to their Cape Town team. Steven will be responsible for sales service support and operating the grinding machine. “Steven has been in the printing industry for over 17 years and has gained valuable experience which will be an advantage in his new role. We are excited about his appointment and the opportunities it brings to enhance our delivery of superior customer service and first class blade sharpening,” said Lynn Stierlin (sales executive at Zanogen Machine Knives, Cape Town).

THE custodian and driving force behind the IPSA Gold Pack Awards for many years, John Marriot, died unexpectedly in February. His involvement with Gold Pack goes back to its inception in the 1970’s and he was invested as a Fellow of the Institute in recognition of his commitment and service. John had a passion for packaging and the packaging industry in South Africa in particular. His enthusiasm ensured that the South African packaging industry’s flag flew high both locally and worldwide. International guests to the annual IPSA Gold Pack awards banquets have hailed

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them as worldclass and ranking with the best. “John’s drive and enthusiasm was shared with those at Marriot Design, who work together more like family than employees. On behalf of all members of IPSA, our condolences go to them and to John’s wife and family. John will be sorely missed by us all,” said Bill Marshall, IPSA National Chairman.

where quality is action

A-PET

Dr Niall Marshall was formerly based in Johannesburg where he worked with Sasol and Ciba. He subsequently moved to Bahrain in the Middle East and joined Everspring Middle East, one of the largest manufacturers of polymer stabilisers and X-ponent Three, which supplies a complementary range of additives and pigments and provides technical and business consulting services

Banana shade structures

SUCCESS OF MIDDLE EAST

AGRICULTURE SECTOR SUPPORTED

BY INNOVATIVE PLASTIC CONVERTERS

FEATURE

50% of the region’s food is imported AGRICULTURE in the Middle East is more than nomadic Bedouins crossing inhospitable deserts with their sheep and camels. In a region that is fully aware of the importance of food security - the original demands of the protesters in Tunisia and Egypt were linked to increasing food prices - food security is an increasingly important consideration. According to the World Bank, 50% of the region’s food is imported and the non-food producing Gulf countries are looking at ways to secure land in third party countries to produce part of their food needs. The 50% of the region’s food requirements that are grown in the region are mostly fruit and vegetables grown in Israel, Jordan, Lebanon and Egypt as well as Saudi Arabia and Iran. The success of the Middle East agriculture sector is supported by innovative plastic converters. Plastics are used in many different ways in agriculture. Nets and nonwoven fabrics are used to provide shade and to protect the plants from hail, birds and insects. Polyethylene sheets are used to line dams and irrigation canals to minimize the water loss due to seepage. Tough, durable plastic pipes are used for irrigation and micro irrigation systems allow vegetables to be grown using the least possible amount of water. Clear plastic film is used as solarisation or fumigation film to prepare the soil before planting and pigmented mulch film is used to modify the soil temperature, limit weed growth and reduce moisture loss. But possibly the most important use of plastics in agriculture is in greenhouses which provide a controlled microclimate by balancing the day and night temperatures, providing an even light and reducing evaporation to maximize the plant growth. It is estimated that there are more than 25 000 hectares of greenhouses in the 54 APRIL / MAY 2012

BY DR NIALL MARSHALL

Middle East (about 37 000 tons of film) compared to less than 800 hectares under cover in South Africa. Not all of the greenhouses are large multi span constructions, many of them are single span structures installed wherever a farmer has space to grow tomatoes, cucumbers, peppers, beans and eggplant. Supplying greenhouse film is not as simple as producing 14 m wide multilayer film, it is about tailoring the performance of the film to the specific needs of the farmers and this requires an attention and long-term commitment to the market that is unusual in most applications. For example, how long should the film last? The answers generally range from one to three years. Achieving the desired lifetime is not the biggest challenge, even in the harsh Middle East climate it is possible to stabilize films to last more than three years but, as the films get dirty and more opaque, the benefit of replacing the film less frequently is offset by the loss in crop yield due to a reduction of light transmitted into the greenhouse. The real challenge is to understand the preferences of the farmers in each slightly different climate and produce a film that matches their requirements. Achieving the desired lifetime is critical, films failing in the middle of a season can lead to the loss of the crop, over-stabilizing the film can result in films being left in the fields only to fail in the middle of the next season. The stabilizer formulation needs to take into account the desired lifetime of the film, the intensity of the sunlight, the thickness of the film and the typical farming practices with respect to the pesticides and fertilizers used both of which can adversely affect the film’s lifetime. The range of greenhouse films available is not limited to different lifetimes. One

It is estimated that there are more than 25 000 hectares of greenhouses in the Middle East (about 37 000 tons of film) compared to less than 800 hectares under cover in South Africa. Pictured here are greenhouses in Jordan and Lebanon

type of greenhouse film which is growing in popularity is the so-called ‘thermal film’ which retains heat inside the greenhouse at night when it can get very cold in arid climates, promoting the important ‘dark photosynthesis’ reactions. Other films are designed to reduce fungal growth inside the greenhouse (allowing for a reduction in the pesticides used) or to promote the growth or early ripening of certain crops resulting in higher yields or better prices and export opportunities for the farmers at the beginning of the season. The successes of plasticulture in the Middle East include improved quality and variety of local produce, the opening of European markets for fruit and vegetables and establishment of export markets for agricultural film. And while the Bedouins continue to follow their herds across the desert, at least they are now able to enjoy fresh vegetables to complement the goat stew. NIALL CAN BE REACHED AT: NIALL.MARSHALL@EVERSPRINGME.COM

PRODUCTS

Flexible seal rings PEEK resin delivers exceptional ductility

ATO manufactures compression moulded seals with diameters from 2.5 cm to 50 cm and thicknesses of 15 mm to 70 mm. The company also develops custom compounds based on KetaSpire PEEK using PTFE, graphite, glass, carbon fibre, and other special materials to meet customer’s demanding performance requirements

FLEXIBLE seal rings from ATO S.r.L., Milan, Italy, a leading compression moulder of highperformance semi-finished goods, are made of KetaSpire® polyetheretherketone (PEEK) resin, manufactured by Solvay Specialty Polymers USA, LLC, for its exceptional ductility for oil and gas, food processing, medical, and pharmaceutical applications. KetaSpire KT-820 PEEK provides greater flexibility and elasticity than competitive PEEK grades, according to Davide Polloni, market development manager for ATO. For example, these parts can be folded or twisted in half and then twisted again into three or four small concentric rings. Compression moulded seal rings made of KetaSpire PEEK can also be softer and easily machined. Flexible PEEK seal rings are manufactured via standard compression moulding and with ATO’s specially designed Hot Compression Moulding (HCM) process. A custom-made HCM machine produces highly elastic, high-performance semifinished parts with 30% elongation, which is

triple that of traditional compression moulding. The elongation test is done on samples manufactured directly from semi-finished products, not from samples made via injection moulding. A special feature of the HCM process is the repeatability of the production cycle through computer-controlled parameters to ensure high quality and highly consistent products. The entire production cycle can be traced by the unique identification label for each semi-finished product. KetaSpire PEEK is produced to the industry’s highest standards and offers a combination of superlative properties that allow it to replace metal in some of the most severe end-use environments. It is one of the industry’s most chemically resistant plastics and offers excellent strength, superior fatigue resistance, and a continuous-use temperature in excess of 240°C. www.atoitalia.com www.solvayspecialtypolymers.com

New PE fuel & water jerrycans A PLASTICS processing company based in Ludwigsburg, Germany, hünersdorff GmbH, has fielded two new types of plastic fuel cans: The ‘Profi’ jerrycans are available as 10 and 20 litre sizes and meet all safety regulations Huenersdorff has also launched the ‘Profi’ can as a 10 and 20 litre water canister version. Both canister types are sackable for space-saving storage. Made of high-density PE, the ‘Profi’ canisters are extremely robust. A useful feature is the special fixture on the canis-

ter’s body for an integrated discharge pipe which fits any standard petrol tank opening. The discharge provided with every jerrycan is suited for modern protection systems against misfuelling. The 10 and 20 litre ‘Profi’ water canisters come in a translucent finish and are also made of HD-PE. The large opening allows for easy cleaning of the can’s interior and for filling or discharging larger quantities of liquid. Both types of canister come with a drain cock with which smaller quantities of water can be dosed.

The new 20 litre jerrycan ‘Profi’ from hünersoerff

www.huenersdorff.de/produkte

Advanced air portable fuel New manufacturing process reduces container weight by 25%, cost by 30% GKN Aerospace has been awarded a £2m, five-year contract with the UK Ministry of Defence for its latest Mark 5 Air Portable Fuel Containers (APFCs). These are being used to transport fuel to inaccessible points such as forward airstrips, helicopter 56 APFC in front line use in Afghanistan

APRIL / MAY 2012

landing zones and forward operational areas. Deliveries are underway and these items are now in service in Afghanistan. These latest fuel containers are 25% lower in weight and 30% lower in cost than previous generations of APFC. This is due to the introduction of an innovative new manufacturing process, developed by GKN Aerospace, which replaces the established

Clariant adds performance to catheter designs A Chinese catheter manufacturer has selected Clariant’s Mevopur – a family of masterbatches and compounds specifically designed for use in medical devices. According to Clariant, the product range improves the functionality and performance of devices and meets the regulatory conditions of the European and US markets. Catheters are a hUSP Class VI regulated item with potential for material migration. Clariant is currently one of the few Masterbatches companies that can offer solutions in this environment, it claims. “Clariant’s strength lies in helping catheter tubing manufacturers to achieve their design and functionality desires using preevaluated materials recognized for their consistency and compliancy with stringent

Mevopur masterbatches and compounds are available in a wide range of medically-approved plastics

regulatory requirements, and backed by a controlled manufacturing environment,” said Steve Duckworth, head of the company’s global medical and pharmaceutical division. “We combine our extensive material expertise and market know-how with the

customer’s expertise and ideas to conduct a risk assessment and design review process that supports them in meeting stringent regulatory requirements.” www.clariant.com

Transparency-boost to cosmetics & baby bottles BOREALIS is taking transparency in extrusion blow moulded PP bottles to new heights with the launch of next generation high-performance grade Borclear™ RC737MO. The new PP grade creates differentiation, cost-efficiency and sustainability advantages for converters and brand owners in the fast moving consumer goods market. Borclear RC737MO is designed specifically for cosmetics and baby bottles and enables production of bottles up to two litres in size. Next generation Borclear RC737MO influences the gloss, haze and clarity of bottles. The haze value, an established indicator describing opacity, can be reduced by 25%.When compared with next best alternatives like metallocene grades, Borclear

RC737MO also offers better surface scratch resistance. Borclear RC737MO can be processed by applying the usual processing settings for random PP grades, with barrel temperatures in the range of 190-220°C. Its higher melt strength enables converters to more easily regulate wall thickness. This enables consistent and enhanced processing combined with good reproducibility as well as greater design flexibility. The lower weight variations will reduce the potential for breakage during transportation and use. www.chemimpo.co.za www.borealisgroup.com

Borclear RC737MO is designed specifically for cosmetics and baby bottles and enables production of bottles up to two litres in size

containers enter service for UK MOD slow and solvent-heavy, rubber-based production with a process which sprays a polyurethane compound paint onto nylon wire. This new process is much faster, lower cost and is virtually VOC (volatile organic compound) free, so far more environmentally friendly. GKN Aerospace APFCs are extremely rugged: able to function effectively at temperatures as low as -26˚C and as high as 71˚C – and will survive down to -46˚C.

The containers are para-droppable, towable and aerodynamically designed to offer optimum flight conditions when under-slung on a helicopter. They are qualified for us in cargo aircraft such as the A400M and C-130.

Preparing the spray booth in the Air Portable Fuel Container (APFC) factory at GKN Aerospace in Portsmouth

www.gknaerospace.com

APRIL / MAY 2012 57

INDUSTRY NEWS

yrs

Hestico celebrates PHOTOS: LOWRIE SHARP

Played important role in the development of plastics manufacturing industry in SA over half-a-century HESTICO, probably SA’s oldest plastic and rubber machinery supply business, is celebrating a major milestone: 50 years of active operation and support of the industry.

But the half-century is a mere statistic, given the number of very interesting personalities that have represented Hestico over the period. At the time of its founding in the 1960s, purchase of production machinery was a difficult undertaking for convertors around the country. The efficiency with which the founding partners of Hestico handled this process has played an important role in the development of particularly, the plastics manufacturing industry in this country. Hestico was founded in Johannesburg in Juanita Stiehler-Brits and Kelvin Mills, managing director and director of Hestico respectively May 1962 by Herman Ernst Stiegler, who had immigrated to SA from Germany, and cialist in packaging, Extensive Conrad Niehaus. At first the company was joined the company. inventory Herman called CF Niehaus & Co and only changed Besides its comHis responsibility was Stiegler, its name to Hestico in 1970 when Niehaus sales of Illig thermoprehensive cusfounder of left and Herbert Seitz joined the company. forming machines. tomer services and Hestico in From inception the company’s sole 1974 was to well trained team 1962, who was also activity was the supply of machinery to become one of of technicians, involved in the plastics and rubber industries, and the Hestico’s standout from the start the establishpartners managed to gain the agencies years: Heiner Wolber Hestico maintained ment of the for some top-flight European machine joined as sales an extensive invenPlastics Federation manufacturers, the first of which included engineer, also tasked tory of spare parts of SA Werner & Pfleiderer, Berstorff and Mann + with sales of D-M-E at its customised Hummel. and related products. premises in Kew, Stiegler was integral to the early success Johannesburg. Heiner actually spent of Hestico. Besides the fact that he was a This enabled the company to offer efficient the rest of his career at the company. popular and gregarious man, Stiegler also By this time the company had grown technical support. oversaw the implementation of the systems and was employing nine people, operating Hestico has exclusive agreements with that enabled the company to operate effrom premises in Richard Street, Selby. a number of top international OEMs, and fectively. Most important was the systems its technicians are Siemens OEM qualified. The wheel kept on turning, however, and put in place to provide technical back-up With this high level of service, the environ- in 1976 Hengst left and opened Bekum to users of the machines it supplied, and SA, which specialized in blow moulding ment at Hestico was in some cases a doing so in a professional and convincing ‘training ground’ where a number of techni- machinery. And Funk departed in the same manner. year: he opened Form Mould Services, cians enjoyed the opportunity to work on As the company which manufactured mould components. high-standard congrew, more agencies Wolber then took over as manager for verting equipment. Stiegler oversaw were added, includD-M-E. Over the years, the implementation of systems ing that of tooling Hestico team has that enabled the company component/hot runner Durban, Cape Town included individuals to operate effectively maker D-M-E of who – with the acqui- Up till that time Hestico had operated Belgium. Responsibilsition of such skills – solely out of Johannesburg, but in 1978 it ity for D-M-E was handed to the late Peter went on to become respected field service started cooperating with Internatio, a Dutch Hengst, who was one of the company’s technicians in their own right. One of these group involved in machinery and matefirst recruits, he had joined CF Niehaus as rial sales which operated outlets around was Norbert Funk, who joined Hestico in a sales engineer. Hengst, who was one the country. Internatio from then acted as 1974 to take over the D-M-E section. The of the most popular figures at Hestico, a sub-agent in Durban and Cape Town, ancillaries side of the machinery business later left to run his own business but then selling and distributing Hestico’s range of was showing huge signs of potential and returned to the company for what was one products. Hengst could not spend enough time on of Hestico’s most successful periods. In 1981 Fritz Kettner and Heiner Wolber D-M-E. A month later, Fritz Kettner, a spe-

1962

Continued on page 60 58

APRIL / MAY 2012

Mould temperature controllers,chillers, granulators

Established 1962

INDUSTRY NEWS

Hestico

yrs

celebrates half-century of service to industry From page 58

South Africa, with a staff of around 40. became directors and shareholders, Herbert Seitz retired in 1992 and Heipaving the way for one of the company’s ner took over as MD. Then, in 1997, Hesheyday periods. tico merged with Affirm Machinery Sales. Unfortunately, Hermann Stiegler died This was essentially the renamed entity after a heart bypass operation in October which Peter Hengst had started when he 1985, shortly after the company moved had left Hestico and formed Bekum SA to new premises in Kew, Johannesburg. in 1976. Hengst had, during his absence, So ended the career of one of the best achieved considerable success with the known individuals in the industry in South sale of Bekum blow moulding machines, Africa, a man whose accomplishments which in the 1970s and 80s were the also included involvement in the setting standard for container production in SA. up of the Plastics Federation of South Affirm had a very strong presence in Africa. the blow moulding market, one of the only Herbert Seitz took over as MD from areas where Hestico was not involved. Herman. Later that year, Herbert’s son Hengst became a Wolf Seitz joined shareholder of what Hestico as a sales Acquisition of several had, with the formaengineer, responsible important new agencies tion of Coprah Infor Dynisco, Mann for blow moulding vestment Holdings, + Hummel, Bareffectively become mag and Werner + equipment a business group. Pfleiderer sales. Hestico, Satcor and Affirm Machinery In 1988 the company purchased a Sales fell under the holding company. 3000m² property in Kew and started Affirm’s entry to the group signified building its own premises. It moved to the the acquisition of several important new new premises in October of 1989, and agencies for blow moulding equipment, has remained there since. including Aoki of Japan (ISBM) and UniThe tie-up with Internatio had an loy (blow moulding and structural foam unexpected spinoff in that, after the Dutch machines). group closed its plastics machinery diviIn 1998 Juanita Stiehler-Brits joined sion in South Africa in 1990, the Internatio Hestico as a sales engineer, responsible managers in Durban, June Smith, and for sales of Arburg machinery as well as Cape Town, Gerhard Greiner, continued certain downstream equipment. working with Hestico. Greiner, along with Hestico’s founding strategy included some Internatio staff, joined Hestico in agreement that directors and staff had to Cape Town. The Cape branch became depart on reaching the age of 60, and this a separate company, Hestico Cape, with clause resulted, obviously, in several indiGreiner as MD. viduals moving on. One notable deparJune Smith took over responsibility for management of Hestico in KZN. Smith and Greiner, who both remained with Hestico for the rest of their careers, helped establish Hestico’s presence in the two coastal cities. Arburg Hestico also inherited the agency for Arburg injection moulding machines from Internatio, a machine line which was to become one of its most popular. Various other agencies – namely Rinco ultrasonic welding equipment and Madag printing equipment – also came to Hestico as a result of Internatio’s departure. By this time Hestico had became the biggest plastics machinery supplier in 60

APRIL / MAY 2012

June Smith, who ran the Hestico business in Durban for many years

ture was that of the popular Fritz Kettner, who left at the end of 2002 and moved with his family to Austria. That in turn resulted in Juanita becoming a director and shareholder. The wheel, as always, kept on turning and the next to arrive was Kelvin Mills, who signed on in 2004, with the intention of taking over from Peter Hengst. Kelvin had worked in the blow moulding area and was well suited to sales of this equipment. Following Hengst’s retirement at the end of 2004, Kelvin took over responsibility for blow moulding. He became a director in 2006. Further evolution was in store too, however. At the K show in Düsseldorf in 2010, discussions with one of Hestico’s top principals, hot runner manufacturer Yudo of Korea, resulted in the Yudo buying a stake in the SA company. This resulted in Yudo CEO Francis Yu becoming chairman of Hestico following the retirement of Heiner Wolber in March 2011. Juanita was then appointed managing director and Kelvin to director. The outcome of this international participation opens opportunities for Hestico, not least as far as trade with the Far East is concerned. Although it has over the half-century supplied mainly European brands, Hestico has more recently begun representing equipment manufacturers in China and Taiwan, falling in line with the many competitors selling machines from the Far East.

www.hestico.co.za

Owen Michaels, who retired recently after over 40 years in the industry, was a popular figure at Hestico Cape

ecoSTAB

TM

LEAD-FREE STABILISERS Tomorrow’s PVC Solutions Today from Sun Ace

BOY’s love model trains! CHRISTMAS this past year was exciting for everybody, but especially so if you were the lucky recipient of a model railway from Märklin. Despite modern electronic toys, the products of traditionrich Märklin of Göppingen remain in high demand worldwide. And supporting the production of these timeless models is German company Dr. Boy GmbH & Co. KG. During 2010 BOY delivered two injection moulding machines with clamping forces of 350 kN and two BOY 22 A machines (clamping force 220 kN). In December Märklin gave BOY a followup order for two more BOY 35 E machines. The energy efficient BOY E-series machines convinced Märklin that they had established the right direction for the future. “The BOY 35 E with the servo drive fits like a glove into our production”, said Wolfrad Bächle, managing partner and responsible for the production at Märklin. “Since we have an enormous number of plastic parts for our railways, railway cars and rail material, we also have a large number of moulds. All of them fit without problems in the BOY 35 E, as the four tie-bar machine has extremely generous distances between the tie bars and platens,” he added. The BOY 35 E is the most compact in its tonnage range and requires a footprint of only 2 m². The machines run in a three-shift operation under full steam. In addition to some of its other features, the extremely low energy requirement of the machine has helped decrease production costs. www.dr-boy.de

EQUIPMENT

Threaded nozzle for hot runner systems Nozzle design provides leak-proof operation SYNVENTIVE Moulding Solutions has introduced a new leak-proof threaded nozzle, the 09E, for use with its line of ‘Plug ‘n Play®’ unitized hot runner systems. The 09E threaded nozzle is available with both thermal gate and valve gate options. It features a 9mm internal flow bore (with 30mm mould cut-out) and is ideal for medium-sized part applications with maximum shot weights of 250 grams per nozzle. Since these nozzles are threaded directly into the hot runner manifold, a leak-proof system is provided without critical stack-up dimensions that must be maintained. These nozzles are externally heated and are available in lengths from 60-400mm. The heaters

are easily replaceable and have integrated, replaceable thermocouples. The 09E nozzles are the latest addition to the Synventive ‘Plug ‘n Play’ hot runner system product line. Synventive ‘Plug ‘n Play’ systems are fully preassembled and tested, and are shipped ready to install in the mould. As such, they greatly reduce the amount of time normally spent assembling, adjusting, and mounting the hot runner system into the tool. Synventive ‘Plug ‘n Play’ systems are designed for use in demanding applications including automotive, premium consumer and electronics. www.synventive.com

Borouge invests in complete pipe extrusion line for new innovation centre BOUROUGE has ordered a complete polyolefins (PO) pipe extrusion line from KraussMaffei Berstorff for its new Innovation Centre in Abu Dhabi. The order package comprises the KME 60-36 B/R single-screw extruder in the successful 36D Series, the KM-RKW 32 and KM-RKW 33 pipe heads, and corresponding downstream components for the diameter range from 12 to 63 mm. Borouge chose KraussMaffei Berstorff because of their extreme efficiency and high flexibility in the use of different materials. The system will

BOY 35 in the production of Märklin

www.kraussmaffei.com

BOY 35 E and a model railway from Märklin

KraussMaffei Berstorff singlescrew extruder KME 60-36 B/R

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be used in the innovation centre’s laboratory to test development stages of various PO materials such as HD-PE, LD-PE, PP-HM or PP-R and also produce pipes of 12 to 63 mm at line speeds of between 2.8 and 100 m/min. The line is equipped with two pipe heads in order to ensure a quick and flexible product change. Borouge’s Innovation Centre will work together with the European innovation centres of Borealis as well as with local and international educational institutions such as the Petroleum Institute of Abu Dhabi, to further develop the competence of polymer science in the United Arab Emirates.

liam.chegwidden@polysaf.com, kelly.dewet@polysaf.com and alan.wassung@polysaf.com (Cape Town)

EQUIPMENT

Advanced internal bubble cooling system Method delivers quick changeovers, major scrap reduction ADDEX Inc of the United States, a leadsors are aimed at the bubble above the ing global supplier of blown film equipfrost line, where bubble size is stable, ment and components, has introduced to calibrate the lower sensors to ensure one of the industry’s most advanced the size is kept constant. The DIBC internal bubble cooling (IBC) systems system includes a fifth ultrasonic sensor for blown film extrusion lines. The Digital that is aimed at a fixed target in order to Internal Bubble Cooling (DIBC) system calibrate the other four sensors whose delivers the fastest reaction time in the readings can be altered due to changes in industry to ensure air temperature. precise bubble conThe 100% digital The DIBC system went trol, helping procescircuit system elimithrough several iterations sors to speed product nates errors caused in terms of software changeovers and by interference due development and creation significantly reduce to electrical devices scrap. like corona treaters of the unique air “We have elevated or ultrasonic sensor regulation valve. the technology to a driftings. Thanks new level, offering to the digital circuitry, one of the most sophisticated bubble the DIBC continues to function if one, two cooling systems on the market,” said or even three of the four ultrasonic senRick von Kraus, president of Addex Inc. sors fail. However, in split-level set-ups, “At a time when resin prices are high and one sensor must function at each level. scrap reduction is a major concern, the The DIBC system is versatile because DIBC represents a major advancement it can be used with 100% blower speed that helps processors realize major raw control (recommended for trimmed films) material savings.” and with the air valve control for the tightThe five-sensor system features a est possible layflat control. User-friendly high-speed, servo-controlled air regulafeatures include a limited number of tion valve that performs split-second buttons and switches along with operacorrections in bubble size (up to 20 adtor alerts that indicate an off-centre or justments per second). Processors have ‘breathing’ bubble. reportedly switched from a 1000mm to a The DIBC system can be integrated 1500mm layflat in seconds, instead of the into any Addex or non-Addex complete minutes it took with the previous system. line control system. One user has reduced annualized waste by just over 30 tons of material, which www.addexinc.com equates to a 1.5 RMS (raw material savings = annual percentage of raw material saved), said Von Kraus. The DIBC system went through several iterations in terms of software development and creation of the unique air regulation valve. Patented split sensors enable the air flow intake and exhaust to react to the slightest changes in bubble size at or below the frost line where the bubble size is not yet final. A set of two non-contact ultrasonic sensors are aimed at the bubble below the ‘frost line’ where size changes, particularly with low melt-strength resins such as metallocenes and LLDPEs. This allows an immediate correction by the intake/exhaust blowers via the AC inverter-controlled blowers. For the more critical layflats, this is done via the highspeed servo reaction control valve. A second set of two ultrasonic sen-

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Addex Inc was founded in July 1989, in Stoughton, Massachusetts, USA, as a supplier of highperformance components for blown film production. It has supplied some of the most sophisticated technologies capable of producing very flat film, without camber, with the lowest possible gauge variation and the highest possible output. The company is a leading manufacturer of many patented blown film components and systems including manual and automated gauge controls, dies, air rings, internal bubble cooling systems, oscillating haul-offs and winders as well as leading designs of gravimetric blenders and bubble cages.

Bubble boost – The new IBC system from Addex of the USA can make up to 20 adjustments of the bubble a second

EQUIPMENT

Super fast F-Series 2-cavity mould produced round lids in cycle time of 2.7 seconds INJECTION moulding machine manufacturer Ferromatik Milacron presented a super-fast F-Series model configured for a packaging application at NPE in Orlando, Florida from 1-5 April. Each of the five machine axes can be powered by either hydraulic or electric drives and these can be combined in whatever manner suits the manufacturing requirements of the user. At NPE the machine featureD electrically driven clamping and plasticizing movements with hydraulic drives for ejection,

Lids produced by the F 80

carriage, and injection. The F 80, with a clamping force of 800 kN, features a size 40 Advanced Performance (AP) injection unit and a three-zone screw with a diameter of 40 mm and with an L/D of 22. With this configuration, the machine delivers injection speeds up to 500 mm/s. The F 80 offers tie-bar spacing of 470 x 470 mm and will use a 2-cavity mould to produce round lids in a remarkable cycle time of 2.7 seconds. The parts have a diameter

of 110 mm, a wall-thickness of 0.52 mm, and weigh 7 g each. The lids will be used for re-usable 0.6 litre containers for foods such as yogurt, cream, or ice cream. Since its debut at K 2010, Ferromatik Milacron has brought five models in the new F-Series to market: the F 80, F 120, F 160, F 200 and F 350. By the end of 2012 Ferromatik will have introduced the complete F-Series line-up. There will be a total of 10 models available, ranging from 500 to 6,500 kN, with 13 injection units in a number of performance classes to choose from. • FERROMATIK IS REPRESENTED BY SES IN SOUTH AFRICA, TEL 011 902 1010

F 80: New modular FSeries with a clamping force of 800 kN

www.ferromatik.com

Improve performance with real-time data monitoring LIVE Monitoring, a South African software house that specializes in the development of real-time production, asset, power and related manufacturing software, has developed various monitoring applications that are successfully deployed and in use in South Africa. Produmax® has been adopted in a number of manufacturing industries, including injection moulding and plastic extrusion, rubber, printing, textiles and packaging. Produmax helps to improve manufacturing performance capability via a visual performance management system that enables manufacturers to monitor production processes in real-time. The recent deployment of the new web enabled Produmax client also means that users are able to access the data from anywhere in the world using a standard web browser. Automould Plastics and Smiths Plastics are two companies which have installed this system onto all their production machinery, offering a single unified view of new and legacy equipment. AutoMould have made extensive input into the reporting system and developed customized displays and reports that enable them to gather data on their processes .These reports enable AutoMould to establish trends and monitor actual production and downtime efficiency against 66

target times. “Produmax has proven to be an invaluable tool to manage. We initially managed to reduce mould change times and downtimes, and now we are reducing cycle times by setting faster targets for our fitters to achieve better running efficiencies,” said Brent Latter, MD of AutoMould. At Automould the Produmax system has been integrated with the Syspro ERP system to automatically gather product and works order details. Smiths Plastics, part of the Metair Group, has also reported great results using Produmax. “Produmax has improved our efficiency by 11% and allowed us to cut down on 10% of clerical staff who were recording the production statistics manually .The power monitoring system has improved our power consumption as well as given us more capacity,” said Rocky van Rensburg, production director at Smiths Plastics. Smiths Plastics also makes use of the messenger module to generate alerts via SMS or email on downtimes. The company also used Livemonitoring’s PowerMon, allowing real-time power usage

The Produmax display consists of a linear graph of current and historical machine performance using colour coding to represent machine status. that After minimal training, personnel are able to tell the status of their entire production floor from a single display

monitoring. The CO2 emissions can also be calculated using this data. Another benefit of the Produmax system include a section where fitters can build a knowledge base of problems and if they reoccur, the fitter can access the stored data for possible resolutions. www.livemonitoring.co.za

ELEKTRA K-TEC MAXIMA VITESSE F-SERIES

Transform ‘difficult’ plastic purgings

to valuable regrind

EQUIPMENT

Low-cost PRS does job considered too risky for expensive granulators MAGUIRE Products, Inc. has enhanced its Purging Recovery System™ (PRS) for transforming purgings into regrind and has received the CE certification required to make the PRS available in Europe. The PRS is a two-stage system that first planes rock-like purgings into small pieces, then reduces the pieces to uniform, highquality regrind. A purging consists of the transitional material that passes through an extruder as the operator shifts from one job or colour to another; typically it is discharged onto the shop floor, hardens, is scraped up and disposed of, ultimately ending up in a landfill. The PRS is the only equipment designed specifically for the rugged work of size-reducing these heavy masses of plastic, according to B. Pat Smith, Maguire’s vice president of marketing and sales. While the PRS is already used to reclaim purgings of many widely used polymers, the new enhanced design extends its applicability to flexible vinyl, which stretches when worked by cutting blades and can jam conventional granulators; and to shear-sensitive polymers like polystyrene, which can melt as frictional heat builds up in standard equipment. The design improvements permit reclaim of 85 Shore A vinyl, such as that

commonly used in wire and cable. “PRS systems now in use by injection moulders who make multiple colour changes consistently recover purgings at a rate of 455 kg per eight-hour shift,” said Smith. “This is accomplished with minimal energy consumption – an average of 7.5 kWh – since the PRS uses three small motors with a total horsepower of 11, as against motor sizes of 100 horsepower or greater for a standard heavy-duty granulator.” An operator loads a purging into the containment chamber of the purging recovery system.

www.maguire.com On the left are samples of the small pieces produced as the rotor knives plane away material from the purging. On the right is the highquality regrind that is produced when the small pieces are processed by a compact granulator beneath the purging recovery system table.

New plant concept for VACUREMA Prime technology Users of this system can produce food-contact grade flakes, pellets users of PET recycling plants are in search of a system that allows them to determine the form of the processed rPET themselves – i.e. choose between flakes and pellets. The new plant concept is a compact and space-saving all-in-one solution – Erema’s answer to the strongly fluctuating rPET market. Due to the extreme price fluctuations for PET flakes it does not always make sense to produce only pellets, as the difference in price to virgin material is too low and there is neither a market nor customers for rPET pellets. Relloy’s EREMA technical team, Doug Scott and Barney Mkhatshwa, with Enrico Anelli, Relloy’s agent for the Cape area

EREMA has developed a flexible plant concept for the proven Vacurema Prime technology which now enables users to produce both foodcontact grade flakes and pellets. The outcome of a market survey that Erema conducted in the USA and Europe was clear: 68

The solution: 3 in 1 The new plant concept for Vacurema Prime technology enables three different operating modes. This way, plant operators can generate the processed rPET in different physical forms to meet market requirements – while remaining flexible as a result. • Mode 1: production of 100% rPET pellets • Mode 2: production of 100% rPET flakes

• Mode 3: simultaneous production of rPET flakes + rPET pellets With the new concept, not only decontaminated, pre-dried and crystallised rPET flakes but also high-quality, melt-filtered rPET pellets can be produced. Both products are suitable for direct food contact and exceed all minimum quality and purity requirements. Batch operation of the Vacurema Prime technology guarantees an exactly defined minimum treatment duration for every single, thin-walled PET flake. Thanks to the individually adjustable batch times the degree of purity and the required IV value can now be adapted individually, regardless of the operating mode selected. • RELLOY IS THE AGENT FOR EREMA IN SA www.erema.at www.relloy.co.za

EQUIPMENT The result is very low dilution of the base material while still maintaining homogeneity in the weld deposit, ensuring an extremely wear resistant, hard coating with an unparalleled bond to the base material

The Eutronic PTA system uses temperatures in excess of 6000°C to almost instantaneously fuse hard-facing powder to the flight of the screw in an extremely focussed arc

Relloy imports microplasma welding system Uses temperatures in excess of 6000°C to fuse hard-facing powder to flight of screw RELLOY S.A. (PTY) LTD, Southern African leaders in the manufacture and refurbishment of wearing parts for plastics conversion machinery, recently imported the latest Relloy managing technology Eutronic® director Dean Toi GAP 2001DC Plasma Transfer Arc (PTA) microplasma welding system from Castolin Eutectic® in Europe.

While Relloy has always used a PTA system for the hard-facing of screws to provide their customers with the highest quality reconditioned and new bi-metallic screws, this new technology guarantees hard-facing of the highest international standard. The Eutronic PTA system uses temperatures in excess of 6000°C to almost instantaneously fuse hard-facing powder to the flight of the screw in an extremely focussed arc. The result is very low dilution of the base material while still maintaining homogeneity in the

weld deposit, ensuring an extremely wear resistant, hard coating with an unparalleled bond to the base material. Relloy has extended an open invitation to all existing and prospective customers to visit their premises to witness the hardfacing process first hand. • CONTACT RELLOY MD DEAN TOI ON 011 452 3724 OR AT DEAN@RELLOY. CO.ZA TO MAKE AN APPOINTMENT.

Most powerful blow moulding machine catches on

The KLS 14D-100 is the most powerful high output machine of the KLS-series with the capability for 28-36 cavities achieving an output up to 11 800 bottles an hour

KAUTEX Maschinenbau of Germany has continued the streak of success with its Long Stroke Machine (KLS) in the USA. For many years the KLS series has provided an optimal high-output solution for the demanding consumer packaging market. Available with standard quick-change systems and 3-layer coextrusion, Kautex can supply complete KLS turnkey solutions, making the series a 70

pioneer for product quality and reduced cost per bottle. The KLS 14D-100 is the most powerful high output machine of the KLS-series with the capability for 28-36 cavities achieving an output up to 11 800 bottles an hour. The standard carriage stroke of 1480mm and a clamping force up to 550KN make this possible. The shuttle technology of the hydraulic mould transport axis reduces the dry-cycle times of a double-station KLS14D-100 machine to 4.5 seconds. This is the ideal specification for processing HDPE bottles as well as PP bottles with handles. Bottles with a high quality surface finish are gently transported by inner-neck grippers that can incorporate optional integrated leak testing. A servo-electrical controlled takeout movement assures the exact positioning of the bottles. An additional benefit is fast bottle size changeover by removing the need for adjustment of the conveyor belt for different bottle sizes. Mould change reduced to just 10 minutes The KLS series features a standard quickchange system, which results a machine solution which is among the most flexible on

the market. With the combined advantages of the component quick-change system and optional bolt-less mould changing, the time necessary for a mould change is reduced to just 10 minutes. Add to this the ability to make process adjustments without stopping the machine, then the overall time to complete a product changeover is significantly reduced. This technology enables the use of high quality materials for the outer layer and a natural finish for the inner layer to ensure the filled product only comes in to contact with clean material. By using PCR material in the middle layer and minimizing the proportion of masterbatch, savings of material and ultimately a reduction of the bottle cost are achieved. In a recent project, a Kautex KLS machine equipped with 3-layer coextrusion technology is being used to manufacture 200-500ml shampoo bottles with a high gloss pearl surface finish. • KAUTEX IS REPRESENTED BY GREENACRES OF MALMESBURY, PH 022 487 2233.

www.kautex-group.com

The PTA utilises temperatures hotter than the ! " ! ! # $ %&' ( ) ' & This unit delivers the latest technology in microplasma welding. Relloy have been aligning themselves with the latest developments in the European market in order to provide European quality in the South African market.

RELLOY S.A.

(Pty) Ltd

27 Mopedi Road, Sebenza, Edenvale, Johannesburg, South Africa P O Box 8190, Edenglen, 1613, Johannesburg, South Africa Tel: +27 (011) 452-3724 Fax: +27 (011) 452-4722 KwaZulu Natal : Adele Eksteen 083 395 2136 Cape : Enrico Anelli 082 465 7639

email: dominique@relloy.co.za Web: www.relloy.co.za

MATERIALS

RTP expands bioplastics line GLOBAL custom engineered thermoplastics compounder RTP Company has expanded its line of polylactic acid (PLA) bioplastic compounds to include impact modified grades suitable for select semi-durable and durable applications. These new compounds deliver enhanced impact strength and higher heat deflection temperatures than are possible with unmodified PLA resin, providing performance that is equivalent to traditional thermoplastics. These new materials, available in both injection and extrusion grades, expand RTP’s PLA-based product line - which includes PLA alloyed with traditional thermoplastic resins and glass fibre reinforced PLA compounds - to also include impact modified, nucleated, and mineral reinforced compounds. Varying levels of impact modification are available providing several combinations of stiffness and ductility. The compounds are available in both opaque and translucent

versions and can also incorporate FDA compliant ingredients. With impact modification, PLA compounds can achieve notched Izod impact performance as high as 30 times that of neat PLA, making it comparable to PC/ ABS. High performance nucleators raise the heat deflection temperature, giving PLA bioplastic compounds performance similar to ABS, HIPS (high-impact polystyrene), and acrylic. PLA compounds are fully colourable and have bio-content as high as 95% depending on additive loading levels. Key applications include injection moulded covers, housings, and structural components for appliance, consumer electronics, furniture, lawn/garden, medical devices, office equipment, sporting goods, tools, and toys.

RTP Company now has a full line of PLA-based compounds that allow bioplastics to be considered for broader use, giving product designers the ability to create eco-conscious products and meet end-use sustainability goals.

www.rtpcompany.com

Packaging system for pharmaceutical PVP sets new standards BASF has developed a packaging system which sets new quality standards: In the future PeroXeal™ will protect the pharmaceutical excipient Kollidon®, based on PVP (polyvinylpyrrolidone), even better against contact with oxygen and subsequent oxidation. This makes it possible to significantly reduce the peroxide level of Kollidon, making the excipient suitable for use in oxygen-sensitive formulations as well. Under the trade name Kollidon, PVP is used in tablets as a binder and as disintegrant. “With PeroXeal™ BASF is setting new standards for excipients in terms of formula stability and purity and can thus help its customers in the pharmaceuticals industry achieve higher levels of patient safety,” says Dr Boris Jenniches, head of Global Business Management PVP at BASF. “With our new packaging concept we can significantly reduce peroxide values to a level comparable with that of naturally-based raw materials. This makes Kollidon a viable alternative to naturally-based raw materials”. The multi-layered and heat-sealed plastic The multi-layered and heat-sealed plastic film of the PeroXeal™ packaging system, used as inner packaging material, is completely aluminium-free and thus more environmentally friendly 72

APRIL / MAY 2012

film of the PeroXeal packaging system, used as inner packaging material, is completely aluminium-free. The transparent PeroXeal film makes the NIR (Near-Infrared Spectroscopy) test possible: The packaging can remain sealed until the product is used, keeping the excipient Kollidon stable. PVP has a long success story: More than 70 years ago the BASF chemist Walter Reppe used acetylene and pyrrolidone to produce a new monomer, vinylpyrrolidone, which itself can be turned into the polymer polyvinylpyrrolidone. PVP is water soluble, but is also capable of absorbing large quantities of water; it is not a skin irritant, poses no health risks, is temperature resistant, pHstable, non-ionic and colourless. Its widely varied properties make PVP ideal for a broad spectrum of applications. As a binder it holds together the individual active ingredients in the tablet to form a homogenous whole, while as disintegrant it ensures that tablets dissolve in liquids and quickly release their active ingredients. The polyvinylpyrrolidones BASF manufactures are used for the most part in the pharmaceuticals sector. www.basf.com

Rotomoulding from Bought a pulveriser ? Need to buy coloured pellets ? We also sell Natural Pellets Natural Powder Colour Compound Powder

Imported, stocked and distributed by: For all your Polymer Raw Material Requirements

MBT South Africa Unit 14, Eastwood Office Park, 11b Riley Road, Bedfordview. PO Box 751775, Gardenview 2047, South Africa. Tel: 27-11-455 2889 Fax: 27-11-455 2937 www.mbtsa.co.za Rob Wainright Lance vd Merwe Helga Classen

082 801 7373 082 901 0477 083 769 4543

Carlotta Stafford 082 600 7403 Paul Gripper 082 456 6659

Cape Town Office 4 College House Village Walk Parklands

S N O I T A V O N N I

to transform the future 13 companies rewarded for their composite innovations THIS year 13 companies and their partners received awards at JEC Europe - Composites Show and Conferences. The programme was created in 1998 with the goal of promoting innovation and each year reveals the composite novelties that will change tomorrow’s world.

CATEGORY: AERONAUTICS Winner: EADS (France) New non-destructive testing system for the inspection of composite parts used in the aeronautic industry.

COMPOSITES

(Copyright: Airbus S.A.S. by S. Bonniol / JEC Innovation Awards)

CATEGORY: SPORTS & LEISURE Winner: MUNICH COMPOSITES GMBH (Germany) BRAID bicycle frame. Copyright: Munich Composites GmbH/ JEC Innovation Awards

CATEGORY: BIOCOMPOSITES Winner: KOMPETENZZENTRUM HOLZ GMBH, WOOD K PLUS (Austria) New composites material 100% based on renewable resources. (Copyright: Kompetenzzentrum Holz GmbH/ JEC Innovation Awards)

CATEGORY: SOFTWARE

CATEGORY: AUTOMOTIVE

Winner: MAGESTIC SYSTEM INC. (USA) TruPLAN advanced material kinematics kernel. Copyright: Magestic Systems Inc/ JEC Innovation Awards

Winner: AXON (UK) The Axon car weighs 500kg with an all-carbon structure designed for scalable production and suitable for new fuel vehicles and prestige vehicles. Copyright : Axon/ JEC Innovation Awards

74

APRIL / MAY 2012

CATEGORY: WIND ENERGY Winner: GAMESA (Spain) G128, the largest wind turbine blade in the world. Copyright: Gamesa/ JEC Innovation Awards

CATEGORY: MATERIALS Winner: SIGMATEX LTD. (UK) Recycling process of waste carbon fibre from various processing technologies to develop yarns, tapes and fabrics. Copyright: Sigmatex Ltd/ JEC Innovation Awards

CATEGORY: CONSTRUCTION CATEGORY: PROCESS

Winner: ACCIONA INFRAESTRUCTURAS (Spain) The world’s longest stress ribbon bridge of its type using pre-tensioned CFRP cables as the main load-bearing members. Copyright: Acciona Infraestructuras/ JEC Innovation Awards

CATEGORY: RAILWAY Winner: TCI (France) Noise suppressor designed and used in the railway environment by the staff during the train manufacturing.

Winner: FRAUNHOFER ICT (Germany) Production process for lightweight structures based on sandwich structures and spraying of resins, typically fibre-reinforced polyurethane. Copyright: Fraunhofer ICT/ JEC Innovation Awards

Copyright: TCI/ JEC Innovation Awards

CATEGORY: MARINE Winner: ASTILLEROS SANTA POLA, S.L (Spain) New composite laminate with high anti-ballistic properties, especially to ensure the safety of maritime traffic. Copyright : Astilleros Santa Pola S.L./ JEC Innovation Awards

SPECIAL PRIZE LG HAUSYS (Korea)

CATEGORY: INDUSTRY

An all-carbon composite structure for an electric vehicle battery pack module (BPM) without steel reinforcement. Copyright : LG Hausys/ JEC Innovation Awards

Winner: AIRBORNE (Netherlands) Thermoplastic composite spoolable pipe system for the oil & gas industry. Copyright: Airborne/ JEC Innovation Awards

APRIL / MAY 2012 75

COMPOSITES

Innovation, automation

& recyclability at THE innovation processes at work in the composite market constituted the main topic at JEC Europe 2012 conferences and trade show which opened its doors in Paris, Porte de Versailles, from 27-29 March. JEC Europe attracted some 1 150 exhibitors and 30 000 visitors. Professionals from all over the world flocked to the three-day event to see the launching of new products, exhibits of spectacular parts, and demonstrations of the most recent technologies. JEC Europe 2012 boasted 49 500 m² in surface area – an average four times larger than any other composite trade show in Europe and elsewhere in the world. The worth of the global composite market went from €38 billion in 2000 to €72 billion in 2011. In a decade, the sector has managed to structure itself around regional, national and international clusters, strategic alliances and research centres. At an average 6%-per-year increase, the market will be worth €91 billion by 2015. Thanks to a large number of remarkable cooperative associations, the composite industry has been able to innovate and increase its capacities in markets where composites are already well established, like marine or construction. For other sectors, specialized clusters have accelerated the penetration of composites, for example, with the use of composites in aircraft structures rising from 35% to 50%. In the automotive sector, transnational value chains are leading to profound changes in areas like structural parts or under-the-hood parts, such as carbon body frames, or nanotubes in the energy storage

JEC 2012 Facts & figures about JEC 2012 • 49,500 m² of exhibiting area • 1 150+ exhibitors in 2012 • 30 000+ visitors • 74% foreign exhibitors • 70% foreign visitors • 96 countries represented

www.jeccomposites.com systems of electric cars. Automation is a broad field that includes things like equipment, software, and the integration of manufacturing steps. The most significant advances over the past decade have occurred mainly in North America and – especially – Europe, which has the highest automation rate: 83% compared to 70% in Asia, to take one example. JEC provided a lot of scope for these processes. Users are being won over more and

more by composite characteristics that match current needs. These characteristics are low weight, strength, thermal insulation, corrosion resistance, acoustic insulation, fire protection, design flexibility, textural possibilities, surface quality, and recyclability. France plays a leading role in thermoplastic composites and plant-fibre-reinforced parts. For example, Normandy is the world’s leading producer of long high-end flax fibres.

BASF presented its novelties for composites at the Paris JEC Composites Show in March, among them more automotive lightweighting innovations. The new Opel Astra OPC sports coupé features a seat pan made from continuous-fibre-reinforced thermoplastic laminate (known as ‘organo sheet’). The plastics used here are polyamide specialties from BASF’s Ultramid® range. This is the world’s first auto seat pan in a mass-produced vehicle that uses this technology. BASF developed two Ultramid specialties for the Opel Astra OPC seat pan: a nonreinforced grade serves as impregnating material for the glass-fibre fabric, while an impact-modified short-fibre-reinforced Ultramid grade is used for overmoulding the preform, creating the required ribs and edges by a classic injection moulding process. The high strength of the fibre-reinforced laminate allows significantly lower wall thicknesses, reducing the weight of the seat pan by 45%. 76

APRIL / MAY 2012

(PHOTO: BASF – THE CHEMICAL COMPANY, 2012)

Three plastic matrix systems hold huge potential for RTM

A conceptual study of a multi-segmented convertible roof module. The component consists of a polyurethane foam core which is sandwiched between carbon-fibre reinforced cover layers BASF’s Lightweight Composite Team is simultaneously investigating the potential that three plastic matrix systems, epoxy resin, PUR and polyamide, hold for

www.basf.com

continuous-fibre reinforcement in resin injection processes suitable for mass production, including in particular resin transfer moulding (RTM).

MGMW future is bright

The MGMW team – Mike Grandcourt, Gunther and Wolfi Maralik

78

energy-saving shredder technology Able to reduce connected loads of single-shaft shredders by 50% WITH the installation of two new VEGA L 1100 single-shaft shredders from Lindner reSource, Lohner Kunststoffrecycling GmbH of Vechta, Germany has vastly improved its energy efficiency in recycling engineering polymers. “By opting for the VEGA L 1100, we have been able to reduce the connected loads of our single-shaft shredders by 50%, at unchanged throughput. This is in addition to significant cost savings achieved in pre-shredding production waste, not least through a significant cut in wear costs,” said Jan-Hendrik Wilming, LKR’s managing director. Based on previous encouraging experience with Lindner’s recycling technology, LKR is now installing an additional Micromat Plus 2000 single-shaft shredder as part of its current capacity expansion drive. Machines from this series are capable of handling particularly large and heavy plastic waste at high volume rates. This investment too was made with low energy consumption and high productivity consistently in mind. VEGA single-shaft shredders made by Lindner reSource deliver throughputs of between 300 and 1500 kg per hour, depending on configuration and equipment level. Users can choose between two rotor diameters (282 and 434 mm), three rotor lengths (540, 1 080 and 1 620 mm), and two blade types (point blade or square blade rotor). The VEGA L 1100 in use at LKR have been developed for shredding hard plastics at low rotational speeds. Due to the special blade arrangement on the rotor, only one blade is www.relloy.co.za

www.recyclate.de

engaged at any given time. This design ensures a controlled draw-in action, reduced noise emissions, and a lower rate of fines in the pellet output. Beyond this, the machine features easy access for screen changes and maintenance work or repairs, to comply with high quality standards. With their throughput capacity of 500 to 800 kg/h, these units are particularly well suited for pre-shredding small-to-medium size batches, e.g., in the form of start-up lumps, larger automotive plastic parts, packaging items or sheet material. Their ability to process the entire range of engineering plastics, including tough or exceptionally hard products such as PE, PC or POM, gives recyclers maximum flexibility. The substantially larger Micromat Plus singleshaft shredders, delivering nominal throughputs of up to 5 000 kg/h, are intended for industrialscale plastics recycling. Their rotor measures 563 mm in diameter, and the customer has a choice between rotor lengths of 1 530 mm, 2 030 mm and 2 350 mm. Three different drive systems are available to meet specific application needs. Versatility is further enhanced by the easily replaceable screens with 10 to 300 mm hole diameters. LKR employs the new Micromat Plus 2000 as a pre-shredder for large monobatches. Apart from large-volume parts and heavy lumps, even contaminated plastics can be processed in this manner. • RELLOY IS THE AGENT FOR LINDNER RESOURCE IN SA www.lindner-resource.com

The two new VEGA L 1100 single-shaft shredders from Lindner resource, installed at Lohner Kunststoffrecycling GmbH (LKR), need only half as much power as previously employed machines while achieving the same throughput. (GROSSBOTTWAR, MARCH 2012)

EQUIPMENT

DEALING directly with its clients and delivering quality on time, every time, are the secrets to MGMW Trading’s success over the past two years, making the company one of the largest refurbishing operations in southern Africa. Gunther Maralik, Wolfi Maralik and Mike Grandcourt said their clients had also provided invaluable and loyal support over the years. “We offer various welding processes in reconditioning for every application the customer needs and we deliver quality on time,” said Gunther. “We don’t deal through middlemen who charge commission; we only deal direct with our customers.” MGMW are able to manufacture new barrels and screws locally, however, with spiraling manufacturing costs, the company has entered into a knowledge exchange with Hitech China who now supplies MGMW with superior quality barrels, screws and other accessories. Hitech China also supplies pipe extrusion plants, profile extrusion, recycling and washing plants and shredders. Hitech recently installed a complete factory in Namibia. Asked what plans MGMW had for the future, Gunther replied: “To expand even further and help build a great future for my two partners.”

Recycling efficiency with

EQUIPMENT

Comprehensive platform for testing wide variety of plastics Testing covers internationally recognized industry standards WITH the new Bluehill® 3 materials testing software, Instron introduces an updated and enhanced version of its proven and widely acknowledged software for measurement, test control and report generation to determine the mechanical properties of materials, structures and components. It offers an even greater number of tailored solutions meeting the requirements of many internationally standardised and application-specific, one-off and volume testing procedures in academic institutions, industrial R&D and QC departments. To this end, the Bluehill 3 materials testing software provides fully programmed application modules for specific areas of use, including testing of metals, plastics, elastomers, textiles, composites and adhesives, biomedical materials or medical and medical devices, along with supporting documentation covering the relevant testing standards. The Bluehill 3 Plastics Application Module provides a comprehensive platform for measurement, test control, and report creation for testing a wide variety of plastic materials and components. The Plastics Application Module includes a collection of pre-configured test methods and supporting documentation that cover a variety of internationally recognized industry standards. These methods and supporting documentation allow for immediate testing after installation and basic training. Pre-configured Test Methods ü ASTM D638 Standard Test Method for Tensile Properties of Plastics ü ASTM D695 Standard Test Method for Compressive Properties of Rigid Plastics ü ASTM D790 Standard Test Method for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials ü ASTM D882 Standard Test Method for Tensile Properties of Thin Plastic Sheeting ü ASTM D1894 Standard Test Method for Static and Kinetic Coefficients of Friction of Plastic Film and Sheeting ü ASTM D6272 Standard Test Method for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials by Four-Point 80

APRIL / MAY 2012

Bending surement, and verifies compatibility with ü ISO 178 Plastics – Determination of the intended test method. During the test, the user can watch the Flexural Properties ü ISO 527-2 Plastics – Determination measurement results in real-time; upon of Tensile Properties – Part 2: Test completion of the test, the software faciliConditions for Moulding and Extrusion tates the creation of sophisticated reports, Plastics including graphs, photos and logos, which ü ISO 527-3 Plastics – Determination of can be directly integrated into other proTensile Properties – Part 3: Test Congrams in Word, PDF or HTML format. ditions for Films The help system and Sheets available in the The Plastics Application Bluehill 3 software ü ISO 604 Plastics Module includes a has been com– Determination collection of pre-configured pletely revamped of Compressive test methods and and provides the Properties user with immedisupporting documentation ate assistance for Bluehill 3 offers usthat cover a variety of method creation and ers the capability to internationally recognized editing, and for more launch standard or industry standards. complex calculauser-defined testing tions and results dismethods directly play. In addition, the help system contains from the desktop and start testing with a examples of commonly used evaluation simple click of the mouse or key stroke, procedures. Finally, the Bluehill 3 User a feature that significantly increases efCommunity Blog provides the user with a ficiency in the test lab. powerful tool for finding useful information The new Expression Builder is ideal for and answers to frequently asked quesprogramming user-defined expressions tions, or posting questions of his own. and calculations for complex evaluations based on the acquired measurement values. To increase the accuracy and • FOR FURTHER INFORMATION, CONTACT repeatability of test results in the day-toADVANCED LABORATORY SOLUTIONS day operations of a laboratory, Bluehill ON 086 0000 ALS (257) OR 3 automatically identifies the load cell or INFO@ADVANCEDLAB.CO.ZA. strain gauge used for the current mea-

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Email: info@advancedlab.co.za Web: www.advancedlab.co.za

MATERIALS

Thermoplastics for the electrical, electronics industries BY THYS DU PLESSIS: TECHNICAL SERVICES MANAGER, PLASTICHEM

Mouldings for domestic and industrial applications have specifically different specs, and choice of material is hence vital WHEN it comes to choosing a thermoplastic for an electrical component, one must be sure in which area of application the part will be used in – as there is a distinct difference in standards and specifications for domestic and industrial applications. In this regard, there are various amorphous and semi-crystalline materials available meeting these stringent requirements. Household appliances Plastic raw materials used for the manufacture of domestic appliances and components have to comply with the International Electro-technical Commission (IEC) standard. The advanced standard IEC 60335-1 deals with electrical, mechanical and thermal hazards as well as fire and radiation hazards from domestic electrical appliances. It covers the safety of devices with a rating of no more than 250V for single-phase appliances and 480V for other appliances. The precise values that need to be achieved depend on the electric current and whether the appliance is to be operated with or without supervision. According to the above standard, a plastic used in unsupervised appliances with a current of more than 0.2A may only be used if the specimens pass two ‘glow wire’# flammability tests. The plastic must achieve a GWFI of at least 850ºC and a GWIT of 775ºC and the test specimen must not be thicker than the corresponding finished component. If the test material does not satisfy these requirements, the tests must be performed on the finished parts and documented. To pass such tests on the finished part is significantly complex and costly. In almost all instances it is only a flame retardant (FR) grade of thermoplastic that will comply with the above standard. Industrial applications Low-voltage switch gear and industrial control devices have to comply with IEC 60947-1 and UL 508. The IEC 60947-1 standard deals with low-voltage switch gear and control-gear where the UL94 GWFI is of high importance, while the UL 508 standard covers industrial control devices like circuit break82

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ers, relays etc. Of importance in this standard are UL94, CTI, HWI and HAI. The UL 508 regulation is valid throughout the world for conductive (live) parts in industrial applications. This regulation concerns devices of up to 1500V which are operated in ambient temperatures from 0ºC to 40ºC. This regulation also applies to industrial control panels which are installed in control devices for motor-operated industrial equipment. See Table 1.

Bayblend® The latest Bayblend® FR 3000 (PC+ABS blend) from Bayer Material Science may be used in articles with ecolabel status. What are ecolabels? Producers are under pressure to voluntarily comply with certain ecological standards relating to the choice of materials and production method. Where plastic-based products are concerned, the relevant criteria mainly involves the chemical composition of

Table 1: Fire resistance test for plastics Source: Polycarbonate and polycarbonate blends for the electrical and electronics industries – Bayer Material Science AG

Materials that meet the household appliances specification include Makrolon®, Bayblend®, Makroblend®, Apec®, Durtethan® and Pocan®. Makrolon® Bayer Material Science has added a few new grades to its already existing range of flame-retardant Makrolon polycarbonates (PC). Two of these grades are Makrolon® 2467 and 6165X , both with excellent flow properties – making it possible to mould very thin, complex and finely structured geometries giving you a V-0 rating at 1.2mm. The flame retardant packages of all new Makrolon® grades are free from antimony, chlorine and bromine and therefore comply with two new EU directives dealing with the disposal of plastics from electrical and electronic equipment, the WEEE and the Rohs. They also fulfill the criteria of major ecolabels such as ‘TCO 05’ and the ‘Blue Angel’.

the plastics. To receive an ecolabel, the plastic used in the article must, amongst other criteria, be free of carcinogenic and mutagenic substances, and the flame retardant packages must be free of bromine, chlorine and antimony. Due to its high level of fire retardance (UL 94 V-O at 0.75 mm to 1.5mm), the use of the Bayblend® FR 3000 series provides an impressive combination of eco-friendliness and fire safety. Typical applications of the current Bayblend® FR 3000 generation materials are audio-visual, computer equipment, household and related appliances. The most important labels are the ‘EU Flower,’ ‘Blue Angel,’ ‘TCO’ label, ‘Nordic Swan,’ ‘Taiwan Green Mark’ and ‘Japan Eco Mark’.

MATERIALS Durethan® Lanxess, producer of Durethan® (polyamide 6 and 66) and Pocan® (PBT), has several flame retardant grades available with V-0 ratings between 0.75 and 3.0mm with FR systems free from red phosphorous and halogens. For example, Lanxess supplies a glassfibre and mineral reinforced Durethan that passes tests according to the upcoming European standard on fire protection in rail transport for specific applications, achieving ‘Hazard Level 3,’ the best possible classification. A trend that Lanxess is responding to with its own developments in numerous projects is the use of flame retardant Durethan® and Pocan® grades in electrical and hybrid vehicles. Pocan® and Creamid® Materials meeting standards set for industrial applications (UL 508 and IEC 60947-1) are Durethan®, Pocan® and ir-

radiation crosslinked PTSCreamid. The demands for current-carrying parts in industrial applications are generally more stringent compared to domestic applications. Of high importance here is the UL 94 GWI, CTI, HWI and HAI. Some typical applications in this sector are industrial control devices, relays, control circuit switches, lighting dimmer systems and controls, circuit breakers. By using an irradiation crosslinked polymer like PTS-Creamid, the use of flame retardant additives is no longer necessary while the properties of the material still comply to UL 508 – and in some instances with much improved HWI test results. The Relative Thermal Index, RTI, also called the temperature index, describes the ageing behaviour of an insulating material. Non crosslinked materials, which are normally used for live parts, lose their insulating properties at elevated temperatures (e.g. at 160ºC ), even after a short time.

From this data it is clear that the irradiation crosslinked V-PTS-Creamid showed a service life of three times the reference material. A further advantage of the crosslinked Creamid is that it can withstand high temperatures of up to 280ºC with lead-free soldering technology and can even peek up to 500ºC for a brief period of 0.5 seconds in the manufacture of small coils. As the demand for more stringent flammability and thermal requirements in plastic parts increases, so does the demand on the raw material and in this regard the raw material manufacturers are continuously developing and improving materials to meet these requirements. • FOR MORE INFORMATION REGARDING THE ABOVE MATERIALS, AS WELL AS TECHNICAL ADVISE, CONTACT THYS DU PLESSIS AT PLASTICHEM ON 0800 006772 OR WRITE TO THYS@PLASTICHEM.CO.ZA

www.plastichem.co.za

Table 3: Materials complying to specifications for industrial applications Source: Focus on flame retardant thermoplastics – Lanxess press release 2011

Table 2: Semi-crystalline materials in accordance with the domestic appliance standard IEC 60335-1 suitable for carriers of live parts in unsupervised operation with current of more than 0.2 amps

Table 4: Comparison of insulating properties

Source: IEC 60335-1, Advanced standard for domestic appliances – Lanxess Deutschland GmbH

Source: PTS – Marketing irradiation crosslinking

Household and similar electrical appliances that are operated when unattended with parts of insulating material supporting connections that carry a current exceeding 0.2 Ampere during normal operation have to withstand GWFItest EN 60695-2-12:2001-11 (VDE 0471 Teil 2-12) 84 and OCTOBER NOVEMBER 2011 at 850ºC GWIT test/ EN 60695-2-13:2001-11 (VDE 0471 Teil 2-13) at 775ºC

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Bayblend® FR 3010 Fire safety (UL-indexing values) wall thickness 1.0 to 3.0mm. • Glow wire flammability index (IEC 60695-2-12) 960ºC • Glow wire ignitability temperature (IEC 60695-2-13) 850 ºC. UL94 VO @ 1.5mm

Gear housing: Kitchen appliance (material selection) IEC 60335-1 • Glow wire flammability index 960ºC • Glow wire ignition test ≥ 775ºC • Comparative tracking index A600V Durethan DP 2802/30 (PA 66 GF 30) halogen-free fulfils these requirements

www.ustech.co.za

Accurate: Fast: Reliable: Plastic identiďŹ cation Thermo ScientiďŹ c microPHAZIR PC Handheld Plastics Analyzer Thermo ScientiďŹ c microPHAZIR PC is a handheld NIR material analyzer designed for rapid on site plastic material identiďŹ cation. The 2.75 lb (1.25 kg) analyzer is battery powered and completely selfcontained for portable analysis. Ergonomically designed for the expert and non-technical user alike, microPHAZIR PC utilizes the power of nearinfrared spectroscopy to save you time & money. IdentiďŹ cation of common plastic types, including: PLA, PET, PP, PS, ABS, PI, PSO, PE, PPS, TPV, PTT,PC, PMP, PBT, PA (nylon), PETG, SAN, EVA, PB, PPO, CA, PMMA, PUR, PI, PVC, PLA, Ionomer, Styrenic terpolymer, Elastomer, POM, Nylon+ABS

Key BeneďŹ ts Include: Save Time: Rapid and accurate results displayed within seconds. Easy to use: Designed for non-expert users, the analyzer is fully automated and requires no user input.

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Ras Al Khaimah Investment Authority

INVESTMENT

continues to welcome SA with arms open wide FROM a bright legacy to an even brighter future, the UAE has emerged as a hub and a centre of investment and opportunity. Among its flourishing emirates, Ras Al Khaimah has recently witnessed astounding growth to become a pilot for business potential in the country. Home to over 50 000 South Africans, the UAE continues to serve as a lucrative platform for business ventures and investments from the country. Trade in the last year totalled over US $1 billion, a substantial 2.7% increase from the year before, with projected increases playing a significant role in attracting South African investments to Ras Al Khaimah, one of the UAE’s fastest rising emirates. Undergoing a rapid transformation to become a centre for tourism, manufacturing, construction, real estate and service, Ras Al Khaimah has emerged even stronger through advanced infrastructure – which includes port facilities, a nearby airport, and express highways – and governmental support that encourages a rapid pace of development. Alongside this growth has been Ras Al Khaimah Investment Authority (RAKIA), which continues to ease the process of business formation as worldwide visitors 86

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make the emirate a home. Providing one-stop solutions from conception to completion, which encompasses licensing across various sectors, including industrial (14%), trading (36%), commercial (14%), consulting and services (29%) and media (7%); flexible setup options that allow investors to test the waters before making a permanent commitment; provisions for land for industrial activities, warehouses and light industrial units, business towers and office space, labour accommodations, executive residences and commercial centre. Among the many flourishing industries within the portfolio of investors with RAKIA, the plastics sector has seen a distinct advantage with regards to the availability of raw materials in the region. When this is coupled with the low cost of production and operations, Ras Al Khaimah holds the distinction along with being closer to target markets that will work to increase ROI. These factors continue to draw in business registration from local (12%), regional (18%) and international investors from India (28%), Europe (20%), Asia/SE Asia (9%), USA (3%), and Russia/CIS (3%), as well as a number of other countries (7%).

Growth in potential markets, expressly swelling Asian economies, presents further business opportunity for companies that establish operations with RAKIA. Beyond the ease of business formation, the benefits of such an endeavour include a lower cost of living that allows for greater profit margins, 100% repatriation on profits and capital, complete ownership in free zones, no tax on import of raw materials and machinery, no hiring restrictions, low rent options for long-term leasing, a dedicated power plant for the industrial parks, as well as land, air and sea connectivity from Ras Al Khaimah to major markets in the Middle East and surrounding regions. Among the emirate’s most valued tenants have been foreign business partners from South Africa, with over 265 African companies that currently operate with RAKIA. They continue to appreciate the distinct cost advantage and accessibility that makes RAKIA a unique choice. Inviting South African investors to step into the region through RAKIA, the investment authority continues to strive to ensure that ventures in Ras Al Khaimah are the most lucrative option available. www.rakiabusiness.com

TECHNICAL

Plasma technology solves critical adhesion problems Cold plasma improves adhesion properties

A GERMAN manufacturer of automotive rain and light sensors which operate windscreen wipers was encountering problems with the adhesion of liquid silicone rubber to polycarbonate, a situation which would almost certainly have led to major production losses. The timeous introduction of an atmospheric plasma process to bond these dispirate materials made on-time production possible. The design of the sensor comprises various plastic material layers which must stick to one another precisely, as even the smallest air bubbles could cause a malfunction. The family-owned company WeberFormenbau GmbH & Co. KG in Esslingen, South Germany specializes in demanding multi-component injection-moulded parts for the automotive, medical and electronics industry. One of their showcase products is the complex polycarbonate optics of rain/ light sensors which they manufacture for a large automotive supplier in an injection moulding process. Adding complexity to the manufacturing of these sensors is the need to protect and thus enclose the sensitive components, and provide a cover layer which will stick to the windscreen.

BY INÈS A. MELAMIES, BAD HONNEF, GERMANY

Incompatible material combinations Since the production of sensor components involves several production steps, Weber-Formenbau expanded their plastic component production areas and invested in new injection moulding machinery. One of these machines produces the polycarbonate lenses from three components. With an overall length of just less than 3cm each, these fibre optics cover both the sensor function for daylight and the sensor function for water (Fig. 1). After a comprehensive visual inspection of each single unit, the pre-moulded parts are overmoulded in the next production step with PBT in a two-component injection moulding machine where the PBT serves as a kind of package which tightly encloses the PC optics on each side (Fig. 2). The viewing faces of the small PC optics remain free during this process. In the next production step, the entire PC/PBT face is sprayed with a coating of transparent LSR (liquid silicone rubber) which forms the contact face to the windshield (Fig. 3 and 4). Since rain/light sensors have to be detachable, and therefore re-usable, in the event of the windscreen breaking, the LSR must allow good adhesion to the PBT packing and the PC lenses. But it was exactly this production step that turned out to be a problem: The LSR, injected as the last component to provide

The rain/light sensor reflects incoming light beams while measuring the light refraction. Transparent LSR forms the cover layer for adhesion to the glass pane

Fig. 1. The highly complex polycarbonate optics of the sensors is manufactured in a three-component injection moulding process (figures: Plasmatreat) 88

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adhesion to the windshield, was repelled by the surface of the polycarbonate lenses. An inspection revealed that there were tiny air bubbles that could have affected light refraction, and the sensor would have received undesired rain pulses. Elvira Postic, MD of Weber-Formenbau said: “900 sensors were due to be delivered within a few weeks, so we immediately got to work looking for the cause and a solution to the adhesion problem.” But neither a modification of the polycarbonate nor tests with various adhesion-reinforcing silicones proved to be the answer. It was only when Clemens Trumm, manager Application Development Centre at Momentive Performance Materials, and the University of Esslingen was consulted on an advisory basis that they realized that the lack of wettability of polycarbonate was due to the PC surface itself, and not to the LSR. The surface energy was too low. Adhesion defects were also caused by localized contamination of the coatings. Trumm suggested treating the component surface with atmospheric plasma and recommended the German plasma specialist Plasmatreat, Steinhagen. Cold plasma improves the adhesion properties The Openair plasma technology developed by Plasmatreat in 1995 for the pre-treat-

Fig. 2. The PC lenses are initially overmoulded with a PBT package

Fig. 3. Section view: Portion of the LSR coating on the left, still uncoated lenses on the right

ment of material surfaces is used worldwide today. Unlike low pressure plasma, this process does not need a vacuum chamber but operates under completely normal atmospheric conditions. The intensity of ‘cold’ plasma is so high that processing speeds of several 100 mN/ min can be achieved (Fig. 5). The heating typically undergone by typical plastic surfaces is less than 30 °C. The system is characterized by a triple effect: It activates the surface by targeted oxidation processes, discharges the surface at the same time and leads to micro fine cleaning. The activation results in a distinct increase of the surface energy so that completely new adhesion properties can be generated. Trials at Plasmatreat have revealed

that the surface energy of many nonpolar plastics can be increased to over 72 mN/m, an optimal precondition for adhesion in the bonding process. Thanks to this technique, it is also possible to achieve adhesion between incompatible plastics without bonding, simply by using plasma. The user benefits not only from the high electrostatic discharging effect of a free plasma beam, but also from its ultrasonic emission speed which effectively removes all loose and micro fine particles from the surface.

Fig. 4. The fully coated rain sensor

treat’s laboratory, spraying with LSR proved to be successful without any negative side effects. There was not a single air bubble and the silicone stuck perfectly to the polycarbonate. A further 800 components were subjected to the same pre-treatment the next day - with the same positive result. In order to allow direct component treatment in the tray, the injection moulder was supplied with a rental system the next day. At the same time a plant concept for initially offline component treatment was developed because the desired integration of the plasma plant could not be done on the spot since all processing sides in the injection moulding machine were occupied. Joachim Schüßler, head of sales for Germany at Plasmatreat, explained: “Unfortunately this

Problem solving under time pressure Weber-Formenbau were left with just five days to deliver the finished components. After testing 100 components in Plasma-

APRIL / MAY 2012

89

Contact us – R.P.S cc: Cape Town: p. 021 510 6903 info@resinprocessingsolutions.co.za Johannesburg: p. 011 708 6309 info@resinprocessingsolutions.co.za

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Resin Processing Solutions

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SA’s leader in the areas of: Two-component metering, mixing & dispensing equipment To process FIPFG (Foamed-In-Place-Foam-Gasket), Epoxy, Silicone, PU Adhesive, Elastomer, Acrylic.

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TECHNICAL is a situation we are often faced with. Our technology provides a remedy with inline pre-treatment. When looking at the new machine we often find that there is no space left to instal the system.” Integrated plasma system However, in the case of Weber-Formenbau, an integration solution was found in co-operation with German engineering specialist kiki Ingenieurgesellschaft mbH and injection moulding machine manufacturer Arburg GmbH + Co KG, Loßburg. The machine was converted and the plasma nozzle now enters the tool downwards from the machine bed - rather than from upwards as would normally be the case. The two cavities are moved by a rotary unit. The overmoulding process of the PC optics with PBT is performed in the upper cavity (Fig. 6). After rotation, the already overmoulded components in the lower cavity are treated with plasma using a pneumatic motion system. The silicone is sprayed on afterwards. The inline process only takes a few seconds. The xy motion system positioned in the machine base is moved into the working range of the tool. A type RD1004 plasma nozzle can move over the adhesion area and activate the surface of the PC optics for long-term stable adhesion to LSR (Fig. 7). Conclusion This application example shows that manufacturers would be well advised to consider the option of automated pre-treatment of plastic surfaces when

Rain sensor functioning In principle, the daylight beam landing on the windshield passes through a lens of the rain sensor and is reflected by the former. The reflection is detected by a photodiode which opto-electronically measures the light refraction. If the glass pane is dry, the entire light is reflected relatively uniformly (total reflection) and passed on to the photodiode. Water drops or water films on the glass, by contrast, disturb the reflection. The more the rain wets the glass surface whilst driving, the lower the light intensity measured by the diode and the stronger the pulses the sensor is sending to the automatic wiper control system.

planning a new production line as the permanent optimization of materials can substantially modify their composition and, as a consequence, their adhesion properties. In the case of the Esslingen-located sensor manufacturer, the production crisis was quickly averted by the use of the plasma process and thanks to the dedicated service by the supplier. “With the Openair technique, we not only completely eliminated the adhesion problem but also substantially reduced the rejection rate,” said Elvira Postic. Weber-Formenbau produces approximately 120,000 rain/light sensors a month and has placed a third plasma plant from Steinhagen into operation. • PLASMATREAT GMBH IS REPRESENTED IN SA BY RESIN PROCESSING SOLUTIONS, TEL: 021 790 1832, ANDRES@ROBATECH.CO.ZA www.plasmatreat.de

Fig.7. The nozzle of type RD 1004 has been integrated into the fully automated injection moulding process

Fig. 5. View into the injection moulding machine: The Openair plasma beam impinges with almost ultrasonic speed on the polycarbonate lenses. Microfine cleaning and strong activation impart new adhesion properties to the plastic material

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Fig. 6. Pre-moulded parts ready for being overmoulded with PBT in the upper cavity of the machine

SOUTH AFRICA Polymers Division

O U R W I N N I N G F O R M U L A S E T S U S A PA RT Carst & Walker has developed sustainable partnerships with leading international suppliers and valued customers for more than 70 — < = = Rubber and Plastic industries. Within the Polymers Division, the following business units provide the customer with the ultimate polymers solution:

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GETTING IT RIGHT Competition Act continues to play active role in transforming SA’s economic framework

LEGAL

By ABENA DANSO, Adams and Adams, Competition Law Practice Group

THE Competition Act, 89 of 1998, has played a pivotal role in the economic transformation within post-Apartheid South Africa. Marked by its agenda to promote and maintain competition within SA, the Act has played and will continue to play an active role in transforming the economic framework of South Africa. The Act recognises the need to: • provide for markets in which consumers have access to, and can freely select, the quality and variety of goods and services they desire; • create greater capability and an environment for South Africans to compete effectively in international markets; • restrain particular trade practices which undermine a competitive economy; and • regulate the transfer of economic ownership in keeping with the public interest. The Act is applicable all spheres of economic activity within SA, with the exception of collective bargaining and collective agreements under the Labour Relations Act. The Act does also not apply to anything done to achieve a non-commercial socio-economic objective. The Act is divided into four sections: horizontal agreements, vertical agreements, abuse of a dominant position and mergers. Horizontal agreements The Act controls relationships between competitors to prevent collusive behaviour (secretly cooperating to do something illegal or underhanded). The basis for this is that competitors may decide that their profits can be maximised if their trading behaviours were co-ordinated, rather than having to compete with one another. When competitors collude they become similar to a monopoly and can therefore raise prices and reduce output to the detriment of the consumer. To guard against this the Act prohibits any agreement between competitors which has the effect of substantially lessening or preventing competition, unless the competitors can show that there are pro-competitive gains and efficiency to be achieved as a result of their behaviour. The Act however strictly prohibits price-fixing, market divisions and collusive tendering by competitors.

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Competitors must be aware of the company they keep. Any forum where competitors meet is viewed with suspicion by competition regulators as these forums are the breeding grounds for competitors to agree to work together collusively. Informal, non- binding discussions about prices, products or any other trading condition between competitors (even if never implemented) are in contravention of the Act. Adam Smith in 1767 said: “People of the same trade seldom meet together, even for merriment and diversion, but the conversation ends in a conspiracy against the public, or in some contrivance to raise prices.” Vertical agreements

travention of the Act. A supplier would also be contravening the Act if it incentivised the distributor to sell at (or above) a prescribed price. The reason commonly used by suppliers for wanting to engage in resale price maintenance relate to the protection of the product’s brand value and image. Although brand protection is certainly a legitimate goal, suppliers should avoid engaging in the practice of resale price maintenance, particularly bearing in mind that penalties of up to 10% of annual turnover could be levelled against offenders. The Act allows for recommended retail prices, as long as the manufacturer/distributor/franchisor makes it clear that the recommendation is not binding on the distributor/ retailer/franchisee and that there will be no incentives or sanctions for failing to stick to the recommended retail price.

Vertical agreements are between parties in a vertical relationship e.g. manufacturers - retailers, suppliers – distributors and franchisees – franchisors. The Act bans agreements between parties in a vertical relationship unless the parties can show that there are pro-competitive efficiencies that flow from the agreement they have with Abuse of Dominance each other. Minimum resale pricing is strictly The Act controls dominant firm behavprohibited and no justification can be given iour to prevent a firm from being able to by the parties for engaging in the practice. monopolise any sector of the market. The Minimum resale price maintenance occurs Act does not aim to condemn dominance when one party in a vertical relationship that is achieved through (i.e. suppliers/ the ordinary course of manufacturers/ “People of the same trade industrial development by franchisors) preseldom meet together, firms, but it aims to ensure scribes the price even for merriment that a firm’s dominance at which the other and diversion, but the does not arise out of antiparty in the vertical competitive conduct. relationship (i.e. conversation ends in The Act defines a firm’s distributors/ retaila conspiracy against dominance in terms of ers/franchisees) the public, or in some market share and market should on-sell contrivance to raise prices.” power. Any firm which has certain goods or market power is considservices. Adam Smith, 1767 ered dominant regardThe enforceless of its market share. Market power is ment of prescribed resale prices can be the power of a firm to control prices, or achieved directly or indirectly. A supto exclude competitors, or to be able to plier may, for example, restrict supply of a behave independently of its customers and product to a distributor if the distributor sells suppliers. at prices below the prescribed price. The Where a firm has a market share of restriction of supply by the supplier is aimed over 45% the firm is said to be dominant. at penalising the distributor for not selling at A firm is presumed to be dominant if it has (or above) the prescribed price and is a con-

LEGAL The Act is a dynamic piece of legislation which has the ability to create an efficient competitive economic environment by balancing the interests of workers, owners and consumers. As long as the creation of a free market economy is a sort after goal, the Competition Act will always find relevance in a developing and developed economy.

between 35% and 45% market share, but the ďŹ rm can may disprove this by showing it lacks market power. In instances where a ďŹ rm has a market share of less than 35%, the ďŹ rm is not considered dominant unless it can be proven that the ďŹ rm has market power regardless of its insigniďŹ cant market share. The Act prohibits a dominant ďŹ rm from being able to: • charge an excessive price to the detriment of consumers; • refuse to give a competitor access to an essential facility when it would be economically feasible to do so; • require or induce a supplier or customer not to deal with a competitor; • sell goods or services on condition that the consumer purchases separate goods or service unrelated to the main item the consumer is purchasing; • sell goods or services below their marginal cost; and • buy up a scarce supply of intermediated

goods or resources which are required by its competitors in order to actively compete in the market. Where a ďŹ rm abuses its dominance, the Competition Tribunal can impose an administrative penalty of up to 10% of the ďŹ rm’s annual turnover in South Africa and its exports from South African during the ďŹ rm’s ďŹ nancial year when it abused its dominance. Mergers Mergers between ďŹ rms are controlled by the Act. A merger occurs when a ďŹ rm/person gains control of another ďŹ rm in one of the following ways: • when a ďŹ rm/person owns more than one half of the issued share capital of another ďŹ rm; • when a ďŹ rm/person is entitled to vote a majority of the votes that may be cast at a general meeting of a ďŹ rm, or has the ability to control the majority of the votes

either directly or indirectly; • when a ďŹ rm/person is able to veto the appointment or appoint the majority of the directors of the ďŹ rm; and • when a ďŹ rm/person has the ability to materially inuence the policy of the ďŹ rm. The Act requires merging parties to notify the Competition Commission of its intention to conclude a merger transaction when the transaction meets certain ďŹ nancial thresholds which have been set out by the Commission. The Commission investigates whether the transaction will have the effect of substantially preventing or lessening competition, by considering the relevant markets in which the merging parties compete in, assessing whether there is a product overlap and the effect on the market, should the merger be approved. The Commission is also authorised to approve or disapprove a proposed merger on the basis of substantial public interest grounds. APRIL / MAY 2012 93

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DESIGN

Bringing design & TUT final year design students show their talent

Yachel Crofts’ elegant design, dubbed ‘La Lumiere’

Mike Wythe, industrial designer and lecturer at the Tshwane University of Technology (TUT), with guest speaker Dr Johannes Potgieter (Chief Director – Innovation & Technology, Department of Trade and Industry), Craig Duff (TUT Industrial Design Programme Head) and Professor Ben van Wyk (TUT Executive Dean, Faculty of Engineering and the Built Environment)

DESIGN continues to have a positive impact on business success in both developed and developing economies. Mike Wythe, industrial designer and lecturer at the Tshwane University of Technology (TUT), believes that if South Africa is to compete on any level it has to invest in design. “As a recent invited member of the BRIC group of countries, we can continue as we are and simply be a minor player of this organisation, in turn giving them a springboard to the lucrative trade potential that exists in sub-Sahara Africa, or we can adopt an alternative route by taking a leaf from their book and invest in design. India, China, Korea and Taiwan are countries that are enjoying the benefits of investing in the power of design. The developed economies of Europe and the UK have also achieved respective success levels by bringing design and industry together - we should and can do the same here in South Africa!,” he added. Dedicated to helping this happen, TUT’s Department of Industrial Design is producing some extremely gifted talent. Evidence of this was seen at the most recent end-of-year exhibition where final year industrial design students presented their final project work – a collection of automatic tea and coffee makers with a modern twist. Although all the projects were of an excellent standard, SA Plastics was particularly interested in those designs which made use of plastics. Among these were: www.tut.ac.za

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WTFU 1.9 Juan Blignaut The WTFU1.9 is a coffee machine with built-in alarm with options for radio and music audio output. Features include touch screen control, USB input , AUX input and SD card input slot. The design uses styrene acrylonitrile as this plastic does not release any toxins into the water. The drip tray is made from polybutylene terephtalate which can withstand heat. Non slip silicon rubber feet prevent the coffee machine from slipping.

THE GREEN TEALARM Andrew Mossop Inspired by green tea and the Chinese Architecture this design uses polypropylene, stainless steel and bamboo. Apart from producing hot water, it incorporates an alarm, AM/FM player and iPod docking station.

DESIGN

industry together THE IBARISTAE ESPRESSO TECHNOLOGY MACHINE

CLOCK ALARM COFFEE MACHINE

Werner Olivier Mike Siconolfi This machine was designed with the tech-savvy user in mind who appreciates the value of time and information. The product is packed with functionality and is designed with the sleekness and cleanliness of the Apple iPhone. It contains a user touch-screen from which all functionality is accessed and is designed with automation in mind. The machine mainly consists of aluminium, DuPont Corian (aluminite, a relative newcomer to the materials field, which can be easily thermoformed) and ABS plastics for all other plastic parts because of if its durability.

The combination of a clock, alarm and coffee machine is interesting and innovative. This design makes use of thermoplastics such as polypropylene and acrylonitrile butadiene styrene – all affordable for the student market and easily recyclable after the product life time.

Henk Swanepoel’s retrodesigned ‘Toasted Bean Wake-up Machine’ would look quite at place in any modern home

COFFEE MAKER Andre Crichton’s red stitched leather, glossy big buttons and large digital display make for a striking yet practical design

Julienne Bernstein This design offers multiple options for alarm times and coffee making, as well as a radio. Three main materials were used: ABS and polycarbonate combination material, polypropylene for all buttons and switches, and clear polycarbonate. Julienne says she chose the materials for their strength and high scratch resistance, as well as their glossy, high quality finish.

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Colour effect pigments training and masterbatch) 11 May – time available for us to visit individual customers if required.

The seminars will be held in: Johannesburg 9 May – Cosmetic Seminar 10 May – Industrial Seminar (packaging

The seminars are free of charge and will start at 09h00, ending at about 16h00, and will include refreshments and lunch.

Durban 14 May – combined cosmetic and industrial seminar Cape Town 16 May – combined cosmetic and industrial seminar 17 May – time available for us to visit individual customers if required.

TRAINING

CORAL Chem in conjunction with its principal, Geotech International BV, will host a training seminar in Cape Town, Durban and Johannesburg during May 2012 about colour effect pigments (glitters, pearlescents, glass and aluminium pigments). The seminar will cover all aspects of colour effect pigments, ranging from their make-up, type, colours and particle sizes available, formulating with them, their use in different solvent systems, as well as care needed when using them in production.

• FOR MORE INFORMATION, TEL: 031 266 0307 OR EMAIL INFO@CORALCHEM.CO.ZA

The funding of education & training in the rubber industry IOM3 Rubber Division’s Education and Training Fund qualifies for socio-economic development element of Broad-Based Black Economic Empowerment Act BY DAVE DUNCAN, SECRETARY, THE RUBBER INDUSTRY WORKERS CO-OPERATIVE LIMITED

NO-ONE can deny that the level of education and training in the Rubber Industry in South Africa is poor. The consequence of this is increased production costs and lower profitability. Numerous interventions to resolve this problem have been attempted over the years, but have always foundered on the issue of funding. In 2010, the IOM3 undertook an initiative to facilitate the skills training of the workforce in the rubber industry of South Africa. Approaches were made to Plastics/SA (formerly The Plastics Federation) to assist through the use of their regional facilities and teaching skills. They agreed and this gave us training facilities in Midrand, Durban, Port Elizabeth and Cape Town. The SETA (Merseta) relevant to the rubber industry had qualifications and unit standards in place and so all we had to do, in order to get the process up to speed, was find students and fund them. In order to create a positive attitude to the cost benefit that a company will achieve by undertaking training on an industry basis, the idea of linking the costs to the skills development portion of the Broad-Based Black Economic Empowerment (BBBEE) legislation was muted. The IOM3 Rubber Division’s Education and Training Fund was set up in 2011 and received 96

some support to get it underway. This fund was tested against the principles of BBBEE and found to qualify for the socio-economic development element of the Act. This gave an immediate points score under BBBEE of 25 for an SMME and 5 points for a big company. We than approached the subject from the economic development element of BBBEE and investigated ways of training people in the industry within the definition of this element of the Act. We found that the formation of a workers co-operative, in which the co-op members would be educated in a classroom and then trained in a commercial operation in a factory environment would fulfill the conditions of the Act. This concept was introduced to the Industry at the IOM3 Conference in April 2011. Since then the Rubber Industry Workers Co-operative Limited has been registered by the DTI. The registration number is 2012/002753/24. Implications for the industry include: • By contributing 1% of after tax profits to the IOM3 Rubber Division’s Education and Training Fund a company can achieve 5 and 25 points respectively in terms of the socio-economic development element of BBBEE. • By contributing 2% of after tax profits to The Rubber Industry Workers Co-operative Limited,

a company can achieve 15 and 25 points respectively in terms of the enterprise development element of BBBEE. In other words; by contributing 3% of profits after tax, a company can achieve 20 or 50 points respectively towards their BBBEE rating, simultaneously providing skills training which will ultimately enable the company to improve both the quality and productivity of their operation. (50 points is a level 6 BBBEE accreditation for an SMME. An SMME is defined as earning less than R35 million turnover per annum). At the end of the day, this initiative is only as good as the number of skilled people it can deliver. We now have in place, in-house and through strategic alliances, the ability to educate - from ABET to PhD. We can train from sweeper to factory manager and then go on to develop the business skills for entrepreneurship. FOR MORE INFORMATION CONTACT: ANTON HANEKOM, TEL: 011 653 4785, EMAIL: ANTON.HANEKOM@PLASTICSA.CO.ZA TONY HESP, TEL: 082 452 7842, EMAIL: HESPFUTURENET.CO.ZA DAVE DUNCAN, TEL: 082 491 0619, EMAIL: DDJD@IAFRICA.COM

Financing of Equipment

Insurance

Forwarding of Goods & Customs Clearing

Forex

Funding of Debtors

Finance to Pay Supplier

Forex

Insurance

Forwarding/ Shipping

Funding of Imports

Customs Clearing

Warehousing

Distribution

Sales

Payment from Customer

MATERIALS

Vinyl, TPEs for medical applications Latest innovations include flexible vinyl with bio-based plasticizer TEKNOR Apex Company, long a leading producer of medical-grade compounds, has expanded its offerings to device manufacturers with innovations in both vinyl and thermoplastic elastomers (TPEs). Recent advances by Teknor Apex with great potential in medical manufacturing include BioVinyl™ flexible vinyl compounds with bio-based plasticizer. Teknor Apex has begun development of flexible vinyl compounds that incorporate phthalate-free DOW ECOLIBRIUM™ Bio-Based Plasticizers, which are manufactured using plant byproducts by The Dow Chemical Company. Under a recently announced joint collaboration agreement, Teknor Apex has been granted the exclusive right to market in North America flexible vinyl compounds containing these plasticizers in certain applications, including medical devices subject to a Dow Medical Application Policy. In uses like tubing and pouches, Teknor Apex expects that these compounds, under the new BioVinyl brand, will provide the performance advantages of vinyl, have a smaller carbon footprint than alternative plastics like polyolefins or polyurethanes, and be more cost-efficient than ‘green’ biopolymers.

Introduced at MD&M a little over three years ago, the Medalist range of medical elastomers now includes a wide range of styrenic, olefinic, vulcanizate, and alloy formulations, with hardness offerings ranging from ultra-soft gels at 25 Shore OO to hard yet ductile compounds at 85 Shore D. Teknor Apex can further broaden customer options by customizing the surface aesthetics, haptics, clarity, and colour

Another recent advance is assembly technologies for TPE tubing. Three new patent-pending systems for use with tubing made from Medalist® medical elastomers enable common-size TPE infusion tubing to bond securely with conventional connectors. The systems include room temperaturecured adhesives, light-cured adhesives, and solvent bonding. Commercially available adhesive and solvent systems used with

PVC tubing either do not enable most TPE tubing to achieve sufficient bonding strength or do not permit sufficient work time for ease of assembly. These new systems achieve bonds exhibiting a retention force significantly greater than the minimum required by device manufacturers, and they include a slow-setting option to allow precise assembly control. www.teknorapex.com

Bayer CO2 project among best ideas for the future Innovative process for producing plastics with carbon dioxide A BAYER project for using carbon dioxide as a component for plastics is among Germany’s most promising ideas for the future. The ‘Dream Production’ research initiative was one of the award winners in last year’s ‘365 Landmarks in the Land of Ideas’ competition. A pilot plant at Bayer’s Leverkusen site is one of the ‘Selected Landmarks 2012’. The CO2 supplied by the power generation industry is to be used for the production of high-quality foams, replacing a portion of the petroleum usually used as a raw material. Each year this competition, under the patronage of the German President, honours 365 ideas and projects that make a sustainable contribution to Germany’s future viability. This year there were more than 2000 applications for the award, which is presented 98

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in six categories. Dream Production won in the science category. Dr Tony Van Osselaer, member of the Executive Committee at Bayer MaterialScience, believes it reinforces the company’s strategy “to focus on sustainable products, processes and solutions to cope with global challenges such as resource conservation and climate change.” The pilot plant at Chempark Leverkusen has been using CO2 from an RWE lignitefired power plant in Niederaußem outside of Cologne to produce a chemical used for the production of the high-grade plastic polyurethane. Industrial production of the CO2-based precursor is scheduled to begin in 2015.

www.bayermaterialscience.com

Bayer test a new technology to produce plastics using carbon dioxide (CO2). This new pilot plant produces a chemical precursor into which CO2 is incorporated. The innovative method is a breakthrough in catalysis research

“FOUR SEASONS” BY NEIL PAUW OF THE PARLOTONES TM

ISO 9001:2008

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Manufacturers of masterbatches, pigments and additives for the Plastics Industry

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CT 021 552 0627 www.masterbatch.co.za

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083 282 8850

MATERIALS

Rhodia-Roquette develop plant-based polymers ROQUETTE and Rhodia Acetow have signed a Joint Development Agreement (JDA) to develop new plant-based polymers. The JDA will enable both companies to leverage synergies bringing together respective competencies in the field of plant-based polymer chemistry. Jean Bernard Leleu, Deputy CEO and Research Innovation Development Director of Roquette commented: “Our goal is to continuously search for new solutions in growth markets and to boost our competitiveness with new technologies. This agreement is an excellent opportunity to speed up the development of a new range of starch derivatives, offering a cost competitive and sustainable alternative to fossil based polymers.” “This JDA will accelerate the launch of new polymers based on renewable raw material, for which the demand is drastically increasing. The plant-based polymer cellulose acetate and cellulose acetate fibre will remain the key products for Rhodia Acetow. This agreement is one first step towards the diversification of our product portfolio,” stated Gérard Collette, President of Rhodia Acetow. Thanks to Roquette’s expertise in starch derivatives and Rhodia’s industrial technologies, some trials of starch acetate production will be carried out from early 2012 providing several tons which will be available for testing in diverse industrial applications. Potential fields of application include paper, paint and dye sectors and pharmaceuticals.

www.rhodia.com

• PLASTOMARK IS THE AGENT FOR RHODIA

www.roquette.com

Permanent antistatic & lubricant systems NEW possibilities to achieve cutting edge permanent antistatic functionality for medical devices and pharmaceutical packaging have been unveiled by Clariant. Clariant’s launch of a permanent anti-static performance additive extends its recently-introduced additive range featuring ISO10993 / USP23 part 87, 88 Class VI biologically evaluated raw materials. The range provides step-

change functionality in such areas as antimicrobial additives, surface lubrication, which may make extra surface coatings unnecessary. Examples of increased functionality include lower surface friction: permanent and immediate lowering of friction between parts reduces force to rotate, slide and actuate may help to improve the functionality of metered dose devices, such as

insulin pens. Further examples include reduction of insertion resistance for catheters or elimination of oils in syringe components. The additive offers an effective alternative to fluorine chemistries. The lower melt viscosity of the additive masterbatch improves mould release and helps avoiding mould deposits in the final product. Additives focused on improving processing and costs are also included within the range, such as nucleants and process aids for faster cycle times and thinner walled products, laser marking for ink-free identification without solvent residues, and stabilizers to protect plastics materials from yellowing and loss of physical properties during gamma sterilization. www.clariant.com Clariant’s launch of a permanent anti-static performance additive extends its recently-introduced additive range featuring ISO10993 / USP23 part 87, 88 Class VI biologically evaluated raw materials. (PHOTO: CLARIANT)

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BOOKS

Life-saving fire protection CELL phones, carpets, or insulating sheets – flame retardants are used in numerous everyday products to prevent them from being burnt or at least to slow down a fire in an emergency. As more and more plastics and other flammable materials are used, flame retardants are gaining increasing importance. The new market study by Ceresana Research forecasts that global flame retardant revenues will rise to approximately US$5.8 billion by 2018. Demand is above all growing in the Asia-Pacific region, with China registering the greatest increase of 7% per year. As environmental restrictions mainly

impact halogenated flame retardants, less controversial alternatives are being developed. The demand for organophosphates and different inorganic flame retardants is rising by 3.5% to 4.3% per year, which is significantly faster than for brominated or chlorinated flame retardants. The up-to-date market report provides detailed descriptions and analyses of the flame retardant market: Demand divided by product types as well as revenues and prices. The study also offers essential market data related to the individual application areas. The most important sales markets are construction materials – especially made from PVC – insulating materials, rubbers, adhesives, and paints & varnishes. Electrical & electronics and transport industry are also studied individually with reference to the world regions.

www.ceresana.com/en/market-studies/additives/flame-retardants-new/

Booming bioplastic industry analysed THE market research institute Ceresana Research expects the global bioplastics market to reach revenues of more than US$2.8 billion in 2018 – corresponding to average annual growth rates of 17.8%. High expectations will be placed on the bioplastic industry in future. With a roughly 48% share of global demand, Europe was the largest outlet for bioplastics in 2010, followed by North America and Asia-Pacific. In 2010, most demand was accounted for by starch-based plastics, followed by poly-

lactic acid (PLA). Other bio-based plastics (PHA/PHB, cellulose, PBS) as well as fossilbased biodegradable plastics accounted for just less than 17% of global demand. Accordingly, biodegradable plastics are currently dominating the bioplastics market with a roughly 92% share. Non-biodegradable plastics based on renewable resources are forecasted to increase their market share from 8% in 2010 to more than 47% in 2018. The current Study on Bioplastics comprises 450 pages, including 57 coloured graphs and 67 tables. An 8-year review as well as revenue, production and demand forecasts up to 2018 – split by application area, bioplastic types, and country – provide the information and tools to make important business decisions.

www.ceresana.com/en/market-studies/plastics/bioplastics

Global report on surfactants CERESANA Research expects the global surfactant market to generate revenues of more than US$41 billion in 2018 – translating to an average annual growth of 4.5%. With a roughly 37% share of global consumption, Asia-Pacific is the largest surfactant outlet, followed by North America and Western Europe. Ceresana 102

forecast countries in Asia-Pacific to increase their shares in the global surfactant market. In addition, South America will see strong growth, above all because of massive increases in production in Brazil. This comprehensive guide offers the decisive advance in knowledge. An 8-year review, as well as production, revenue and demand forecasts up to 2018 provide the information and tools to help make important business decisions. All data is split by application areas, surfactant types, and countries.

Physical testing of plastics PHYSICAL Testing of Plastics is the latest release by iSmithers Rapra Publishing. This book discusses the physical rather than the chemical examination of the properties of polymers on the basis of the type of equipment used, examples of the applications of these techniques are given. Techniques examined include thermal analysis (thermogravimetric analysis and evolved gas analysis), dynamic mechanical analysis and thermomechanical analysis, dielectric thermal analysis, ESR, MALDI, luminescence testing, photocalorimetry testing and the full range of equipment for mechanical, thermal, electrical, rheological, particle size, molecular weight. www.polymer-books.com

REACH for the polymer industry a practical guide REACH for the Polymer Industry - A Practical Guide is a new release by iSmithers Rapra Publishing. The book has been produced by the EU Leonardo Project called Polymer REACH. The overall objective of Polymer REACH is to develop an e-learning platform and training materials for the European polymer industry to learn and understand how to manage their obligations under the European legislation - Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH). The book will be useful to anyone who works with polymers or the chemicals that are used to make polymers, whether they are end-users or suppliers. REACH is affecting everyone concerned with the polymer industry and this book will help them to prepare for the impact and consequences of the REACH legislation.

www.ceresana.com/en/market-studies/chemicals/surfactants www.polymer-books.com

WORLD NEWS

Umeco exhibits at the opening of the National Composites Centre in the UK showcased its involvement in sectors such as automotive, aerospace and renewable energy

AROUND THE WORLD

UK’s National Composites Centre opens UMECO plc, a leading composites solutions provider in the UK, recently presented a number of exhibits to showcase the company’s expertise in the composites industry at the official opening of the National Composites Centre (NCC) on the Bristol & Bath Science Park near Bristol Umeco was one of the NCC initial members last year and has a place on the NCC board with principal manufacturing and

engineering companies Airbus, GKN, RollsRoyce, Vestas and Agusta Westland. Umeco exhibits showcased its involvement in sectors such as automotive, aerospace and renewable energy. These included a Delta Motorsport E-4 Coupé electric car, a Ginetta F400 sportscar, the root section of a tidal turbine blade and a wing section. Peter Chivers, Chief Executive of the NCC said: “The NCC is a powerful national asset

MEXICHEM BUYS WAVIN FOR €531M

late last year. Last December Wavin announced it was granting Mexichem access to its books, having received assurances on a number of issues relating to a possible post-takeover environment for the company, including strategy and employees’ future. In a joint statement, the two businesses said there was a “compelling strategic rationale” for the takeover.

MEXICAN chemicals giant Mexichem has purchased the Dutch pipe making company Wavin for €531-million, creating one of the world’s biggest plastic pipe manufacturing businesses with a turnover in excess of €4bn. The transaction follows two unsuccessful attempts by Mexichem to buy Wavin

to maximise the potential of the industry. It has something for all businesses involved in composites manufacture, across all industry sectors. I am delighted to have UMECO as one of our Tier 1 members and value their insightful and multi-sectoral contribution.” www.acg.co.uk www.nationalcompositescentre.co.uk

The combined group would have “stronger design, engineering and R+D capabilities whilst leveraging Mexichem’s low cost manufacturing platform,” as well as having “a more diversified end-market profile across the residential, non-residential and infrastructure segments exposing it to different economic and construction cycles”. www.mexichem.com

New Clariant Innovation Centre will provide 500 new research jobs THE cornerstone of the new €100-million Clariant Innovation Centre was officially laid during a ceremony on 29 February at the Industriepark Höchst in Frankfurt. Attending the event were Hessen State Finance Minister Thomas Schäfer; Clariant Executive Committee member Christian Kohlpaintner; and Ulrich Ott, Managing Director of the company’s operations in Germany. Over the next several months, the Swiss specialty chemicals corporation will build an innovative office and laboratory facility of roughly 36 000m2 on a site that will soon

provide jobs for some 500 researchers. The concept for the building, which aims to offer an optimal working environment through its open architectural design, was developed by the Düsseldorf-based architectural firm of HPP. “Innovation is the foundation of the future, both for individual companies and society as a whole,” said Dr Christian Kohlpaintner, whose responsibilities at Clariant include Research and Development. “I hope that the bright and transparent rooms will not only be the birthplace for new ideas that flourish and grow, but also provide the environment for an

inspiring exchange between our researchers and technicians, as well as with their partners in the fields of science and industry,” added Dr Kohlpaintner. He also emphasized Clariant’s targeted research policy: “We want to develop products and procedures that yield sustainable benefits and represent true progress.” He underscored that a major focus in the future will be on megatrends, such as functional materials, energy efficiency and renewable raw materials. www.clariant.com

Clariant Innovation Center Cornerstone Laid at Industriepark Höchst. The cornerstone symbolizes this: Right next to it is a sealed stainless steel tube containing the building certificate, construction permit, construction drawings and a local newspaper – as well as a 3D model of the Depal molecule. Depal is the acronym for diethyl phosphinic acid aluminum salt – the chemical name of Clariant’s successful flame retardant. The molecule will remain visible to the visiting public under a glass panel in the floor of the building. (PHOTOS: CLARIANT)

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AROUND THE WORLD BRASKEM’S GREEN PLASTIC IN STADIUM SEATS

The Fabergé Big Egg Hunt will have 2½ foot fibreglass eggs placed across London which will be exclusively adorned & decorated by some of the world’s leading artists, all to raise money for Action for Children & Elephant family.

Plastic egg for world’s biggest egg hunt for the endangered Asian elephant. A LONDON-based architecture practice Members of the public will be able FourfourSixSix worked with laserto hunt down the strategically sintering specialist EOS and rapid placed, giant eggs, which have prototyper Ogle Models to create been exclusively designed, a plastic egg for the world’s bejewelled and decorated biggest egg hunt, The Fabby some of the world’s ergé Big Egg Hunt, which leading artists, architects, is taking place this Easter, jewellers and designers reports Plastics & Rubber including Mulberry, Sir Weekly (www.PRW.com). Ridley Scott, Zandra From 21 February, Rhodes, Diane Von the UK capital becomes Furstenberg, Marc Quinn, home to 200 giant, Bruce Oldfield, The Chapuniquely crafted Easter man Brothers, Theo Feneggs, of which the lasernell, William Curley (who sintered egg will be one. The sintered egg has designed the world’s They are all destined to will help raise cash most expensive chocolate become highly collectible for good causes egg), Bompas and Parr works of art and will be availand Polly Morgan. able to buy at auction, with proIt is hoped that their sale will ceeds going to Action for Children and raise £2m. Elephant Family, the UK’s biggest funder

BRASKEM, the leading thermoplastic resin producer in the Americas and the world’s largest producer of biopolymers, established a partnership with Amsterdam ArenA to supply Green Plastic to be used in the production of seats for the multifunctional Dutch stadium. In addition to the 52 000 existing seats, 2 000 new seats manufactured with Braskem’s plastic made from ethanol will be installed in the coming months. By the end of the next two years, all 54 000 seats will be made of plastic from 100% renewable raw material, using Brazilian technology. Braskem has produced Green Plastic since September 2010, when the company inaugurated the world’s largest plant of ethylene made from ethanol in city of Triunfo (Rio Grande do Sul state), with annual production capacity of 200 ktons of polyethylene. Unlike fossil plastic, Green Plastic presents a positive environmental result: each ton of plastic produced avoids the emission of 2.5 tons in carbon dioxide. www.braskem.com

SABIC VENTURES FORTH! THE Saudi Basic Industries Corporation (SABIC) has launched a new global corporate venture capital arm, SABIC Ventures, in the Netherlands, with the primary goal of seeking out innovative technologies and businesses consistent with the company’s global strategy. SABIC Ventures aims to build up a portfolio of technology options for the company’s future businesses. It will do this by investing directly both in seed stage, early stage and late stage companies. The new organization will lead investment, co-lead and invest alongside venture capitalists. SABIC Ventures will be funded by an Innovation Fund, which will be managed by the organization. Amongst the areas which have been designated for investments are advanced materials and composites; alternative feedstocks for chemicals and materials; and alternative energy and cleantech. At the same time, the organization will be constantly exploring new areas of interest. The targeted countries for sourcing venturing investments are the USA, Europe and Asia. www.sabic.com

BASF TO BUILD 300 000 TON TDI PLANT

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BASF will build a single-train 300 000 metric tons per year production plant for TDI (toluene diisocyanate) and expand additional plants for its precursors at its site in Ludwigshafen. These include the construction of a new hydrogen chloride recycling plant as well as the expansion of plants for nitric acid, chlorine and synthesis gas. It is also planned to expand the aromatics complex at the site for the supply of toluene. Total investment including the required infrastructure at Ludwigshafen site will be about €1 billion and create around 200 additional jobs. Production will start at the end of 2014. BASF plans to close down its 80 000 metric tons per year TDI production plant in Schwarzheide, Germany, when the new plant goes on stream. TDI is a key component mainly used for flexible polyurethane foams. www.basf.com

SABIC to manufacture TDI, MDI The agreement was signed by Mohamed Al-Mady, SABIC vicechairman and CEO, and Mitsui Chemicals president Toshikazu Tanaka at SABIC’s headquarters in Riyadh on 26 February

Lanxess to break ground in Singapore for world’s largest Nd-PBR plant LANXESS will break ground for its new neodymium polybutadiene rubber (Nd-PBR) plant in Singapore in September. Lanxess plans to invest roughly €200 million in a 140 000 tons per annum facility in Jurong Island Chemical Park. The facility will be the largest of its kind in the world and serve the growing market for ‘green tyres’, especially in Asia. The plant is expected to start up in the first half of 2015. Lanxess has signed contracts with key suppliers to its Nd-PBR plant. Petrochemical Corporation of Singapore (Private) Limited (PCS) has agreed on a long-term supply of butadiene to Lanxess. Butadiene is the raw material Lanxess needs to produce Nd-PBR. PCS is building a new butadiene extraction unit and associated infrastructure necessary to supply the raw material. Singapore’s TP Utilities Pte Ltd will provide steam to the Nd-PBR plant. TP Utilities is adding 650 tons per hour of steam capacity to its existing biomass clean coal cogeneration plant on Jurong Island, which currently has 500 tons per hour of steam capacity and 100 Megawatt of electricity generation capacity. Nd-PBR is used in the treads and sidewalls of ‘green tyres’. It helps reduce the rolling resistance and increase the fuel efficiency of a tyre. Nd-PBR is highly resistant to abrasion and plays a significant role in making tyres more durable and safer. Performance butadiene rubbers are also used for the modification of plastics in the manufacture of High-Impact Polystyrene (HIPS) for injection moulding applications. Other applications include golf balls, running shoes and conveyor belts. Lanxess’ new Nd-PBR plant will be located on Jurong Island next to the company’s butyl rubber plant, which represents the company’s singlelargest investment at €400 million. It is currently under construction and will come on stream in the first quarter of 2013. www.lanxess.com

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G20 nations urge global cooperation to tackle economic crisis, promote growth SUSTAINABLE economic growth for a secure world was the theme of the third G-20 consultation meeting held in Riyadh, Saudi Arabia from 24-26 February. Discussion centred around energy for sustainable development, and the sovereign debt crisis and its effects on the world economy. Othmar Karas, vice president of the European Parliament, partially blamed the ‘incomplete monetary union’ created by the European Union for the crisis some Member States are currently going through. Karas explained: “While we established strong policies, we also left loopholes, which made it possible for Member States to apply very different financial and economic policies – some that were inappropriate and that triggered our current crisis.” But Karas pointed out that the EU wasn’t the only one responsible. “The economic crisis has its roots in excessive deregulation and the unsustainable

credit policies that were adopted in the United States. And in this respect, the EU has also fallen victim to the poor choices of other policy makers,” he added. Emphasizing the need for a reinforced global cooperation, Karas called for a review of the International Monetary Fund and the World Bank. “The world has changed, but unfortunately the Bretton Woods system has not. I am not saying the IMF and WB should be closed, but it is time to review these organizations.” Han Qide, vice chairman of the standing committee at China’s National People’s Congress, highlighted the ‘constructive’ role played by emerging markets in resolving the financial crisis. “Developing countries have become formative participants in improving the global economic governance and the international community should fully recognize and support the positive contribution they made to the world economy,” he concluded.

On the invitation of the Speaker of Majlis Ash’ Shura of Saudi Arabia, and under the patronage of the Custodian of the Two Holy Mosques, King Abdullah Bin Abdulaziz, the G20 conference was attended by representatives from Argentina, Brazil, Canada, China, India, Indonesia, Italy, Japan, Korea, Mexico, Russia, Saudi Arabia, Turkey, and the European Parliament.

WORLD NEWS

Mr Akira Yonemura, managing director of Petrochemical Corporation of Singapore (Private) Limited with Dr Axel C. Heitmann, chairman of the Lanxess board

THE Saudi Basic Industries Corporation (SABIC) has signed a TDI and MDI technology license agreement with Mitsui Chemicals, Inc. Mitsui will provide manufacturing technology for producing TDI and MDI, which are both raw materials for producing polyurethane. The agreement also provides for joint technology development in TDI/MDI. Expressing strong optimism over the agreement, Mohamed Al-Mady, SABIC Vice Chairman and CEO, said that it would spearhead a strategic collaboration between the two companies to explore future possibilities to collaborate in the PU business. “It will enable a fast development of PU application industries in Saudi Arabia, especially with regards to thermal insulation which will contribute to employment creation as well as energy savings,” he said.

DIARY

Complex fluoropolymer parts being injection moulded PERFORMANCE Plastics presented examples of their high volume fluoropolymer injection moulding capabilities at the National Plastics Exhibition trade show from 1-5 April in Orlando, Florida. Performance Plastics is one of the few injection moulders in the world who can point to the successful and repeatable implementation

of PFA and FEP using a direct gating, hot runner moulding system with up to 8 cavity tools to mould critical parts for the medical, computer printer, lithium ion battery and semiconductor industries. Direct gating of hot runner systems for PFA and FEP provides significant cost reduction due to the elimination of runner

material while providing better dimension and tolerance control. Hot runner system component design, specially formulated tool steels and sophisticated processing techniques are combined to allow high volume production at a competitive cost. www.performanceplastics.com

2012 EVENTS SPE 8TH THERMOFORMING CONFERENCE

LATEST DEVELOPMENTS IN MIDDLE EAST PLASTIC PIPES

THE European Thermoforming Division of the ‘Society of Plastics Engineers’ will host their 8th Thermoforming Conference in Venice, Italy on 26-27 April. The conference will include presentations from experts in the thermoforming industry and lively debates in workshops about technical and commercial issues. The conference will be complimented by an informative and comprehensive exhibition of relevant latest product developments and services offered by a variety of leading suppliers to the thermoforming industry. www.e-t-d.org

AFTER the success of the previous events, AMI’s 5th edition of the Middle East Plastic Pipes Conference will take place from 15-16 May at the Shangri-La Hotel in Dubai, UAE. This event is focused on the applications, markets and technology for plastics pipes in the Middle East region. In 2011, the economic output of the MENA (Middle East & North Africa) region grew by circa 5% compared to 2010 and this rate is expected to be maintained through the next 5 years. Investments are outpacing economic growth: they represented circa 25% of GDP in 2011 and are expected to reach circa 28% by 2016. The region’s population continues to grow fast, further stimulating demand for construction and infrastructure – and hence the demand for pipes. Middle East Plastic Pipes 2012 is a unique forum to debate the technical and market developments in the pipe industry in the MENA region. www.amiconferences.com

PLASTPACK GHANA THE Plastpack series of industry shows in some of Africa’s leading markets continues in Ghana in May. Plastpack Ghana 2012, the specialized industry trade show for plastics and rubber industry, takes place at the Ghana International Trade Fari Centre in La Accra from 3-5 May. The event promises to be a platform to forge business alliances, showcase products and services and interact with traders in the West African region. The event is organised by Al Fajer Information & Services of Dubai. www.plastpackghana.com

PLAST 2012 APPROACHES TAKING place from 8-12 May, PLAST is the largest exhibition in 2012 representing the entire production chain of machines, equipment, moulds, raw materials, regenerated materials, composites, and semifinished and finished products for the plastics and rubber processing industry. By the end of December over 1 100 exhibitors from 40 countries had signed up for the event, but more applications have been submitted in recent weeks. With respect to previous editions of the triennial exhibition, PLAST 2012 has many new features underscoring the international character of the fair and highlighting the broad panorama of novel technologies and innovative applications that will be prominently displayed in the huge Fiera Milano pavilions. Regarding innovations, from now until May there will be an increasing number of exhibitors highlighted on the website www.plastonline.org with a symbol allowing interested parties to get a preview of their innovations and pre-organize their visit to PLAST 2012. A notable feature this year is the return of the satellite fair RUBBER 2012 during PLAST. www.plastonline.org

KREYENBORG’S 6TH SYMPOSIUM ON PLASTICS PROCESSING NEW trends in the plastics industry is the topic for the Kreyenborg’s Group’s symposium from 9-10 May in Muenster / Westphalia. At this symposium a panel of keynote speakers will give a hint of the future, will present new ideas and will develop them further through personal discussions with a wide range of key industry executives. Top-class guest speakers will give a precise idea of the latest trends in plastics processing – in terms of dosing, compounding, extrusion or filtration technology. Additionally an insight into the Kreyenborg Group’s solutions as well as new developments and the related possibilities for the process technology will be given. www.kreyenborg.de/symposium2012

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Propak West Africa EUROPEAN THERMOFORMING CONFERENCE: 26-27 April NH Laguna Palace, Venice, Italy: www.e-t-d.org NPE 2012: 1-5 April: Orlando, Florida, USA: www.npe.org PLASTICS IN THE AUTOMOTIVE ENGINEERING 6-7 April: Mannheim, Germany: www.vdi.eu PLASTICS JAPAN: 11-13 April Tokyo Big Sight, Japan: www.plas.jp/en INDOPLAS 2012: 11-14 April Jakarta, Indonesia: www.indoplas.com UTECH EUROPE 2012: 17-19 April Maastricht, Netherlands: www.utecheurope.eu IISRP AGM: 16-19 April: Venice, Italy: www.iisrp.com 4TH PAINTEXPO: 17-20 April: Germany: www.paintexpo.com SAVA ‘BEST PRACTISE PVC’: 17 April PlasticsSA, Midrand: www.savinyls.co.za WASTE MNGT & RECYCLING CONFERENCE: 18-19 April: Emperors Palace, Kempton Park graces@mogorosicomms.co.za CHINAPLAS 2012: 18-21 April Shanghai, China: www.chinaplasonline.com

MONTGOMERY West Africa is pleased to announce the launch of PROPAK West Africa, a brand new event for the emerging West African packaging industry, taking place from 4-6 September 2012 at the EKO Hotel and Conference Centre in Lagos, Nigeria. PROPAK West Africa 2012 is aimed at manufacturers and suppliers involved with food processing, packaging, printing, labelling and plastics - providing an exciting forum for trading, product sourcing and education. It will give decision-makers, specifiers and buyers leading-edge information on global trends, advancements in technology, product information and market updates. Furthermore, the exhibition will provide an ideal platform for local and international exhibitors and visitors to network. “There is so much potential for this show in the West African region,” says Lydia Botha, New Business Development Manager, Montgomery Africa. “Not only does our market research

indicate a high demand for this kind of event, but we’re excited to be providing a platform for suppliers and potential buyers in this region to exchange ideas about some of the fascinating trends and developments in the packaging industry”. According to Botha there are many fascinating facets to explore when it comes to the packaging industry, including: innovative ways to utilise packaging as a marketing tool, new technological advances that capture attention and sales, how packaging can aid food preservation, as well as environmental considerations. PROPAK West Africa is organised by Montgomery West Africa, which through its subsidiary, Specialised Exhibitions (Pty) Ltd has run PROPAK Africa for over 20 years in South Africa. The announcement of PROPAK West Africa, comes at a time when the event organisers have long recognised the potential for a show in one of the world’s fastest growing economies. The

DIARY

DIEMOULD INDIA: 19-22 April Mumbai, India: www.demat.com POLYMERS IN PHOTOVOLTAICS 2012: 24-26 April Maritim Hotel, Cologne, Germany: www.amiplastics.com

Intelligent process integration

ZIMBABWE INT’L TRADE FAIR: 24-28 April Bulawayo, Zimbabwe: www.zitf.net

INTELLIGENT process integration for maximum efficiency and economy – this will be Engel’s focus at Plast 2012 from 8 to 12 May in Milan. Five highly-integrated and automated production cells will demonstrate the injection moulding machine manufacturer and automation expert’s system solution and technology competence – and across a wide spectrum of applications, too, from automotive through technical moulding and packaging to medical. The biggest growth driver in Italy today is the automobile and automotive supplies industry. At Plast, Engel will show how oil sumps, made of polyamide and produced in MuCell® foam technology, are made on an Engel duo 3550/500 pico injection moulding machine with a clamping force of 500 tons. The production cell is automated with an Engel viper 20 linear robot. Due to increasing focus on lightweight constructions and the increases in raw material prices, the trend will be for structural foam moulding. Physical foaming involves the injection of pressurized nitrogen or carbon dioxide into the plastic melt during plastification. After injection into the unpressurised mould, the gas separates from the melt and creates a fine-cell foam structure. This saves raw material, weight and costs. At the same time, the moulded parts exhibit excellent dimensional stability. Under the Engel foammelt banner, Engel offers turnkey solutions from a single source for MuCell structural foam moulding. The foam units by Engel technology partner Trexel, Woburn/USA, are fully integrated into the Engel injection moulding machine’s CC 200 control unit. This means that the overall system satisfies the highest demands with regard to documentation, traceability and clarity. When it comes to manufacturing technical parts, the Engel victory machines use their tie-bar-less advantage to the full. An Engel victory 330H/200V/120 combi will demonstrate

SPE THERMOFORMING CONFERENCE: 25-27 April Venice, Italy: www.e-t-d.org DRUPA 2012: 3-16 May: Dusseldorf, Germany: www.drupa.com PLASTPACK GHANA 2012: 3-5 May La Accra, Ghana: www.plastpackghana.com BIOPLASTICS COMPOUNDING & PROCESSING: 8-9 May Miami, Florida, USA: www.amiplastics-na.com/Events WAITEX: 8-10 May: Lagos, Nigeria: www.exhibitionsafrica.com AFRICA INFRASTRUCTURE: 8-11 May ExpoCentre, Johannesburg: www.africainfrastructure.co.za PLAST 2012: 8-12 May Fiera Milano, Milan, Italy: www.plastonline.org PLASTPACK GHANA 2012: 10-12 May Accra, Ghana: www.plastemart.com ARABIAMOLD 2012: 14-17 May Expo Centre Sharjah, UAE: www.euromold.com PLASTIVISION ARABIA 2012: 14-17 May Expo Centre Sharjah, UAE: www.plastivision.ae MIDDLE EAST PLASTIC PIPES: 15-16 May Shangri-La Hotel, Dubai UAE: www.amiplastics.co.za EAITE 2012 (EAST AFRICA INT’L TRADE EXHIBITION) 20-22 May: Dar-es-Salaam, Tanzania www.africainfrastructure.co.za 108

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debut in September West African region is poised for phenomenal growth and at the very centre of it all, Nigeria boasts a GDP in excess of $200 billion. With the Nigerian market now eager to source world-class offerings, this show provides a professional and centralised platform to highlight the untapped potential of this region. PROPAK West Africa will be co-located with FoodPro West Africa, Pro-Label West Africa and Print Expo West Africa at the premier international, EKO Hotel and Conference Centre, located on Victoria Island in Lagos, from 4-6 September 2012. The show organisers, Montgomery West Africa, form part of the Montgomery Group, which has staged some of the world’s most prestigious and acclaimed exhibitions since 1895. Montgomery Africa is a market leader in producing international and local events, with a proven history of delivering a solid return on investment for both exhibitors and visitors. The company also manages a number of African-based events on behalf of

international partners, including Grand Designs Live, IP EXPO and IFSEC South Africa Co-Located with OSH Expo Africa and FM Show Africa. PROPAK Africa, a bi-annual event, held in Johannesburg South Africa is the largest and most successful packaging, food processing, labelling, printing and plastics exhibition held on the African continent, an event that skilfully harnesses the synergy and strengths of the various inter-linking industries. The exhibition attracts local and international buyers from all over Africa and beyond. In addition to this portfolio of events is PROPAK Cape, a highly successful regional event taking place in the Western Cape, South Africa, alternating in a three-year cycle with PROPAK Africa. “We look forward to expanding on the phenomenal success of PROPAK Africa and PROPAK Cape through the launch of this new event in West Africa,� says Botha. “The market is ready for this and we aim to deliver a world-class experience,� she concluded.

If you are involved in packaging, printing and labelling purchasing decisions for your organisation, then you don’t want to miss Propak West Africa in September

COMPANIES INTERESTED IN EXHIBITING AT PROPAK WEST AFRICA, SHOULD CONTACT LYDIA BOTHA, NEW BUSINESS DEVELOPMENT MANAGER, MONTGOMERY AFRICA ON + 27 11 835 1565 OR LYDIAB@MONTGOMERYAFRICA.COM. www.propakwestafrica.com APRIL / MAY 2012 109

is Engel’s focus this at the fair. The machine will produce bottle openers in two-component injection moulding and insert technology with in-mould labelling. An Engel viper 12 type linear robot – the fastest robot in its load-bearing class in international comparisons – inserts both the metal part and the decorative foil into the mould. The ďŹ rst shot initially injects the body of the bottle opener in polycarbonate, while the second applies a covering of TPE to the edges to provide a better grip. Thanks to the Engel victory machines’ tie-bar-less design, the robot can access the mould from the side, thus supporting automation on a very tight footprint. Both the robot and the magazine for the metal inserts and foils are inside the machine’s safety guarding. The highlight by Engel medical at Plast is the production of syringe barrels including needles in a single production step. An all-electric Engel e-motion 200/100 T injection moulding machine featuring a clean room design is used for this. To allow this to happen, the needles are separated and inserted into the 4-cavity pilot mould by Zahoransky, Freiburg/Germany, by a linear robot driven by a servomotor. After overmoulding with a COC/COP, the syringe barrels are taken off the mould by an Engel easix multiple axis industrial robot. Because the take-off step occurs in parallel to insert-placing of a new set of needles, the plant achieves extremely short cycle times. The integrated process is an innovation compared with legacy multiple step processes, which ďŹ rst manufacture the needle holder in an injection moulding step and then glue in the hollow needles.

THE LARGEST AND MOST SUCCESSFUL PACKAGING, FOOD PROCESSING, PLASTICS, LABELLING AND PRINT EXPO IN AFRICA NOW COMING TO WEST AFRICA

Ek Conveo Hotel an d n Lagostion Centr e , 4 - 6 S Nigeria ,

E BOO PT 2012 K YO STAN U D NO R W!

Propak West Africa™ A brand new event for the emerging West African packaging industry, running in conjunction with Print Expo West Africa™ and Pro-Plas West Africa™, this exhibition will target manufacturers, suppliers and service providers involved in the packaging, food processing, printing, labelling and plastics industries. Meet professionals and decision makers from within the packaging, processing, printing, labelling and plastics industries Network with stakeholders within your relevant supply chain

conferences and workshops that will run concurrently with the exhibition Promote your products and services Increase brand awareness

For more information go to www.propakwestafrica.com Associates:

Media Partner:

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www.chinaplasOnline.com

PDM12 (PLASTICS DESIGN & MOULDING): 29-30 May London, UK: www.pdmevent.com GLOBAL PLASTICS TRADE & MARKETS CONFERENCE 11-12 June: Istanbul, Turkey: www.cvent.com BIO-BASED MATERIALS: 19-20 June Stuttgart, Germany: www.hanser-tagungen.de MASTERBATCH 2012: 19-21 June Renaissance Hotel, Vienna, Austria: www.amiplastics.com WORLD SYMPOSIUM ON PERFORMANCE FILMS 20-21 June: Düsseldorf, Germany: www.ihs.com/spf2012 INTERPLAS THAILAND 2012: 21-24 June BITEC, Bangkok: www.interplasthailand.com MULTILAYER PACKAGING FILMS USA 2012 26-27 June: DoubleTree Hotel, Chicago, USA www.amiplastics-na.com/Events SAITEX (AFRICA’S BIG SEVEN): 15-17 July Gallagher Convention Centre, Midrand www.exhibitionsafrica.com EUROMOLD BRASIL: 20-24 Aug Joinville, Brazil: www.euromold.com INTGERPLAST BRAZIL: 20-24 Aug Joinville, Brazil: www.messebrasil.com.br GLOBAL POLYMER INNOVATION EXPO: 26-29 August Columbus, Ohio, USA: www.globalpolymerinnovationexpo.com

DIARY

PROPAK WEST AFRICA: 4-6 September Eko Hotel, Lagos, Nigeria”: www.propakwestafrica.com SPE AUTOMOTIVE COMPOSITES CONF: 11-13 September Michigan, USA: www.4spe.org TAIPEI PLAS 2012: 21-25 September Nangang Exhib Hall, Taipei: www.taipeiplas.com.tw MEDIPLAS: 25-26 September Birmingham, UK: www.mediplasuk.com ARMO 2012 (ROTO MOULDING): 30 Sept-2 Oct Lyon, France: www.armo2012.com WASTECON 2012: 8-12 October ELICC, East London: www.wastecon.co.za BRITYREX INTERNATIONAL 2012: 9-11 October Manchester, UK: eci-international.com@mimimail4.com AFRIMOLD 2012: 10-12 October Gallagher Convention Centre, Midrand: www.afrimold.co.za MULTILAYER PACKAGING FILMS 2012: 16-18 October Martim Hotel, Cologne, Germany: www.amiplastics.com/Events POLYOLEFIN ADDITIVES 2012: 23-25 October Martim Hotel, Cologne, Germany: www.amiplastics.com DRINK TECHNOLOGY INDIA: 6-8 November Mumbai, India: www.drinktechnology-india.com PACKTECH INDIA: 6-8 November Mumbai, India: www.packtech-india.com PETPOINT: 13-15 November Brau Beviale, Nürnberg, Germany: www.drinktec.com WIND TURBINE BLADE MANUFACTURE: 27-29 November Maritim Hotel, Cologne, Germany: www.amiplastics.com EUROMOLD 2012: 27-30 November Frankfurt, Germany: www.euromold.com 110

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High-precision 16-cavity mould NyproMold Inc of the USA exhibited some of its latest technologies at the NPE show in Florida in April. The company has been in operation since 1988, when it was formed jointly by global plastics component supplier Nypro and other investors. In the last 7-10 years NyproMold’s business has shifted from being a mouldmaker to a start-to-finish mould solutions provider, to Nypro as well as many market-leading companies who need a full service mould solution with the capability to execute globally. The mould in this image is used for the multi-cavity production of 10.5g inhaler bodies, running at a cycle time of 17 seconds. NyproMold operates two plants in the USA at which it employs over 150 people. It has exported over 500 moulds over the past few years. www.nypromold.com

NYPRO is a $1.2-billion turnover supplier of complex plastics manufacturing solutions servicing the healthcare, packaging and consumer & electronics industries. It is one of the largest employeeowned companies in the world, with 17,000 employees at 41 locations in 14 countries. Its HQ is in Massachusetts, USA. www.nypro.com

Polymers in photovoltaics manufacturing er market for several years and will THE AMI Polymers in Photovoltaics give the opening address – a market conference aims to bring together study on the challenges for the leading polymer industry experts industry in the next few years. Other alongside the solar industry to topics to be discussed include quality discuss the optimum, cost-effective control, cost-effective manufactursolutions for components such as ing, module design and polymer encapsulants for silicon, back sheets usage, and extrusion technology for for protection, lightweight alternative encapsulants. materials to glass in front sheets, and new substrates for silicon depowww.amiplastics.com sition, sealants and adhesives. The next international conference PHOTO: SOLAR SAILOR HOLDINGS AUSTRALIA, WWW.SOLARSAILOR.COM on Polymers in Photovoltaics 2012 will take place from 24-26 April at the Maritim Hotel in Cologne, Germany. Dr Henning Wicht has been studying the solar pow-

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Karbochem 49 Luigi Bandera 17 Magnum Machine Tools 19 Maritime Marketing 77 Masterbatch SA 99 MBT 73 Mercury Plastics 35 MGMW Trading 79 Miracle Mould 36, 37 MJH Machine Tools 20, 21 Nissei ASB 15 PCA Training seminar 47 Performance Colour Systems 83 Perspex SA 13 Plasquip OBC Plastamid 45 PlastiChem IFC Plasticolors 29 Plastomark 65 Polysaf 63

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PET Injection Technician vacancy at bottling plant in Eastern Cape, Tsitsikamma. Requirements: s -IN YRS EXPERIENCE IN 0%4 )NJECTION -OULDING WITH PROVEN record and references of previous employer(s) s #AN SET UP COMMISSION OPERATE AND MAINTAIN )NJECTION -OULD machine s +NOWLEDGEABLE IN ALL ANCILLARY equipment s (AVE A ZERO WASTE AND preventative maintenance attitude s !PTITUDE FOR TECHNICAL PROBLEM solving s 7ILLING TO WORK OVERTIME when necessary s 7ILLING TO RELOCATE s 3ALARY NEGOTIABLE Send applications to: cv@tsitsikammacrystal.co.za

APRIL / MAY 2012 111

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SPORTS

Solvay marks 25yrs of PARA resins SOLVAY Specialty Polymers is celebrating its 25th anniversary as the global supplier of Ixef® polyarylamide (PARA) resins. Since its development in 1986, Ixef PARA has provided a unique combination of strength and aesthetics, making it ideal for complex parts that require both overall strength and a smooth surface. To commemorate this milestone, Solvay has commissioned a 25th anniversary edition of a commercialized archery bow to demonstrate Ixef PARA’s unique and valuable performance attributes in structural applications. For metal replacement applications, Ixef compounds typically contain 50-60% glass fibre, giving them high strength and rigidity. Even with high glass loadings, the smooth resin-rich surface delivers a high-gloss, glass-free finish suitable for painting or metallization. In addition, the high-flow material can readily fill walls as thin as 0.5mm even with glass loading as high as 60%. Structural parts made from Ixef resin can be simultaneously very thin, extremely rigid, strong, and dimensionally stable. The tensile strength of Ixef compounds is similar to many cast metals and alloys at ambient temperature. Over the years, Ixef PARA has found significant success in structural parts for transportation, medical, food, chemical processing, semiconductor, mobile electronics and plumbing applications. Ixef compounds boast excellent colouring capabilities and select grades are formulated for flame-retardant applications. Solvay manufactures Ixef resin at its plant in Rheinberg, Germany, and compounding is done at various plants throughout the world. The commemorative archery bow, manufactured by Plastiques-Paillard, a France-based injection moulder, clearly illustrates the strength, flexibility, and aesthetics of the 50% glass-filled Ixef resin. The bow stands out as a unique application amid the typical structural parts made of Ixef compounds. The 1.5 m-long bow, which is sold primarily in Europe, has a mono-block design that allows for the frame to be injection moulded in one piece from the high-flow 50% glass-filled material. The strength and power of the archery bow can be enhanced by increasing the fibre content of the resin compound by up to 60%. www.solvayspecialtypolymers.com To commemorate Solvay Specialty Polymers’ 25th anniversary as the global supplier of Ixef® polyarylamide (PARA) resins, Solvay commissioned a 25th anniversary edition of a commercialized archery bow to demonstrate Ixef PARA’s unique and valuable performance attributes in structural applications

112

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No more slippery tee-offs! No matter how sweaty your palms when it comes to taking that first swing, Monprene compounds from Teknor Apex will keep your grip secure

No more slip with ‘Wet-Grip’ Monprene products retain their rubber-like traction when wet A NEW series of ‘wet-grip’ thermoplastic elastomer (TPE) compounds for injection moulding promises to add to the enormous popularity of soft-touch features in consumer products by retaining a nonslip surface and secure grip even when wet. Monprene® Wet Grip Series styrenic block copolymer compounds minimize or eliminate a problem encountered with many standard TPEs in soft-touch applications like sports equipment grips, handles, knobs, and cushions. These products often become slippery and hard to handle when wet from sweat, rain, humidity or other commonly encountered substances. Unlike the standard TPEs, the new Monprene products retain their rubber-like traction when wet, while providing the same elasticity and other key mechanical properties. They are available in hardnesses from 10 to 45 Shore A and can be applied onto a variety of substrates by means of two-shot, co-injection, or insert moulding. In tests measuring the coefficient of friction of a standard styrenic TPE with a Monprene wet-grip grade, the new compound exhibited a coefficient that was 25% greater when surfaces were wet with plain water and 175% greater in the case of soapy water. Soft-touch components that are potential applications for the new Monprene compounds include those in shaving razors, toothbrushes, writing instruments, paint brushes, hair brushes, hair dryers, hand tools, kitchen appliances, cooking utensils, vacuum cleaners, mops, rakes, shovels, scissors, and sporting equipment. • ADVANCED POLYMERS IS THE SA AGENT FOR TEKNOR APEX. www.teknorapex.com

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