s.a. plastics '011 12 smaller by SA POLYMER TECHNOLOGY

by the way ... 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.

Volunteers help keep coast clear – Doing their bit during the International Coastal Clean-up were this group of volunteers, who spent a Saturday morning helping to remove plastic litter and debris from the Hout Bay harbour … which should help make the experience of visitors to the popular Cape venue over the summer season that much more positive. Due partly to the large quantity of litter and the lack sometimes of effective municipal services, plastic litter continues to be a problem in South Africa’s urban areas. So it’s thanks to volunteers such as these gentlemen and, especially to Douw Steyn and the PlasticsSA environment team, who coordinated the coastal clean-up effectively again this year. More info on page 24.

Zimbabwe getting busier WE HEAR from across the border that activity in the industry in Zimbabwe is improving. It’s incredible that manufacturers in the industry there have managed to survive such a long period of political intervention and economic stagnation. The most obvious way to detect improvement in an industry is whether demand for raw materials is increasing, and that is currently the case with our neighbour’s material suppliers. It appears now that figures in the Zim government have finally realized that the benefits for their people are better if industry is allowed to do what it’s supposed to do, manufacture goods and sell them.

Kenya hopes to host standards conference THE Kenya Bureau of Standards (KEBS) was happy about the article we published about the ‘Plastic Pipes for a Sustainable Future’ conference presented in Nairobi in September. The fact that KEBS is organising such industry events is positive, since it’s in the interest of all participants in an industry to agree on and promote responsible standards. Kenya is vying to host an ISO (International Standards Organisation) TC 138 (technical committee for plastic pipes, ﬁttings and valves) conference in 2014. Clement Pius Chomu, manager for engineering standards at KEBS, said unexpectedly positive support for it had been encountered at a plenary meeting held in Amsterdam in October. Japan is the other country which is offering to host the event, in Kyoto. For many international businessmen, Africa is one of the most exciting continents to visit, and long may it last. Let’s vote for the Kenyans!

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

EPP safe bet for helmet design – pg 96

HAVE … IF YOU Y NG TO SA : if you SOMETHI de e bright si Look at th wisdom to e gem of have som to us at e rit w ease impart, pl .com s@iafrica saplastic

Find out more at www.saplastics.co.za

Volume 9 Issue 6

DECEMBER 2011 - JANUARY 2012

Contents INDUSTRY NEWS Gold Pack Awards: Good performance by industry

Propak Cape packs them in!

Lomold: Size does matter when talking ﬁbres

PEOPLE Focus on toolmaker, moulder Hiwalt

Cabletech celebrates success with Borch

PRODUCTS First all-plastic wheel rim with BASF’s Ultramid® PA

New applications for PA, PBT

TECHNOLOGY Famox: Fast mould change system from Engel

Major order for Motan in Mexico

‘Monosandwich’ method from Ferromatik

two-component part of PP, TPE

DIARY Events coming up in 2012

SPORTS Gyrocopter: Roy Miller, Lowrie Sharp take off

ON THE COVER Lanxess’ Macrolex colorants meet numerous legal conditions for use in food packaging and toys. Other beneﬁts are high colour intensity, outstanding brilliance, good weather resistance and lightfastness and excellent heat stability. The range has now achieved Food and Drug Administration approval from the USA. Lanxess has been working with Eastman Chemical in the process of colouring its ‘Tritan’ polyester for products that achieve a balance of clarity, toughness, dishwasher durability and high heat and chemical resistance. Please see page 82 for the full story. www.lanxess.com

THIS ISSUE New solutions – Finding new solutions has been the order of the day in the packaging sector, which involves not only looks and appeal, but more cost-effective production and effective disposal for recycling/resource recovery … a trend which is becoming important for all areas of the plastics, composite and rubber sectors PICTURE: MILLIKEN (USA) / SEM PLASTIK (TURKEY)

TOUGH CONDITIONS

Martin Wells

, Publisher

BRING OUT BEST IN SOME! Surprise surprise! – some converters have managed well

COMMENT

2011 is drawing to a close and for most converters and suppliers it’s been tough … and if it wasn’t tough it’s been challenging. The global economic conditions coupled with demands to improve environmental performance in our products and processes placed almost all businesses under pressure. And if that’s not enough, the customary annual ‘inflationrelated’ increase has gone out the window: when supply contracts are renewed, many customers (certainly the big operators) now request a decrease! Seen against this background, the strike in mid-year was almost certainly the low point of 2011. Under heavy pressure, the last thing most converters needed was to have to deal with workers demanding more. But – surprise, surprise! – some converters managed well. And the reality is that few people know who the successful businesses are. One of the characteristics we notice is that successfully run converting operations tend to prefer to keep quiet about their success. Why? Making too much noise could attract unnecessary attention, from opposition, from SARS … even from the dreaded paparazzi! But how have these operations managed in the difficult trading conditions? For a start, it’s become more difficult for any old body to open and compete with established players. Most of the converters in the industry in Southern African are run by individuals or small groups of directors, often family businesses. It’s a fine balancing act for business owners to retain important people in their organisations, but the simple fact is that employers need good technical, sales and financial management – and the lack of even one of these spells trouble. And then the business owner also needs to be an HR guru! It’s obviously difficult

DECEMBER 2011 / JANUARY 2012

to be good in all these areas, and the hallmark for success is probably the ability to realise what you’re not good at, and get someone who is, to handle these areas. Overall, the tough trading times have brought out the best in some operators. PlasticsSA Possibly the main highlight for the industry of 2011 was the emergence of PlasticsSA as the new industry governing entity. In the South African socio-economic-political situation, it’s inevitable that trade organisations need to renew and rebrand. People in the industry are still referring to the ‘Federation,’ but that will probably disappear. The PlasticsSA team is involved in numerous training and environmental projects which are helping the industry grow from within, as well as project a better public image. Thank you to Anton Hanekom and the PlasticsSA team for keeping the ﬂag ﬂying. 2012 It’s likely that economic conditions will not improve in the near future, so we can probably expect trading conditions to remain challenging. The example set by the successful companies – and thankfully some of them are featured in the Gold Pack Awards (pages 8-11) and Propak Cape (pages 12-19) articles – is something we can all strive for. Best wishes to all of you for a happy and relaxing festive season. You’ll need it: next year we’ll have to come back even stronger!

JUST BRIEFLY TAIGAN M-STRETCH TAIGAN Trading, one of SA’s top suppliers of ‘stretch’ films, has changed its name to reinforce its marketing and sales objectives. The Johannesburgbased company will from now be known as Taigan M-Stretch. Considered as a McCullough at work “pallet wrapping specialist,” McCullough founded the company in 2005, realizing a life-long ambition to become an independent player in this highly competitive market. He had previously while at Tristar been involved in the introduction of 3-layer cast film in SA. The multi-layer films began to make pallet stabilisation as well as other stretch applications a genuine possibility (previous films used to stretch and elongate but did not retain their strength). Taigan markets and sells only high quality imported stretch film. Its success has been based on its ability to support its customers with on-time and dependable supply. McCullough realised from ‘day 1’ that his customers were the most important link in the supply chain. The films it supplies – which now include high-performance 5 and 7-layer structures – are also marketed under the brand ‘Taigan M-Stretch’. www.taiganm-stretch.co.za

INDUSTRY NEWS

Massive mould for wind turbine blades 50m blades weigh 12 tons, mould comes in at over 44t ONE of the largest moulds for composite production ever used in South Africa has been installed at Isivunguvungu Wind Energy Converter in Cape Town. With its two halves weighing a whopping 44 tons, the mould is to be used for the production of 50m wind turbine blades. Each blade will weigh approximately 12 tons, with the glass ﬁbre reinforcement and resin each constituting about half that. The mould was built in China for Gurit of Switzerland, a leading global supplier of advanced composite materials for the wind energy market. Gurit supplies both infusion and prepreg blade technology as well as all

the relevant materials needed for building composite blades. Isivunguvungu (Zulu for ‘big storm’) Wind Energy is the brainchild of Dr Michael Kast, who was previously involved in composite boat manufacture (he designed the yacht ‘Broomstick’ which won the Cape-to-Rio race in 1993). Kast has been engaged in the wind energy sector for the past 10 years and managed to assemble the group behind

From ‘waste’ to ‘virgin’ System enables Durban converter to run as much as 60% reprocessed material NEXT GENERATION Recycling Machines of Austria contributes to the fulﬁlment of demands for a reduction in production waste to virtually zero, in which regard Spunchem International of Durban had reason to celebrate recently: its use of one of NGR’s ‘One-Step’ recycling systems over the past 10 years has enabled it to reduce production scrap to extremely low levels. More than a decade has passed since Spunchem, one of the largest and most modern manufacturers of non-wovens and geo-textiles in Africa, was faced with the challenge of selecting a system for the recycling of waste from its PP nonwoven production. After trials, it selected an S:GRAN 65 HD recycling system from NGR. One of the advantages of the NGR system, as opposed to comparable 6

DECEMBER 2011 / JANUARY 2012

recycling technology, is that it removes the uneconomical need for separate and additional, upstream preshredding. Users can consequently benefit from enormous cost benefits. At the time it was impossible to know that the ‘One-Step’ recycling system would turn out to be something of a phenomenon. The machine has already been running untiringly and reliably for an entire decade, without any screw replacement or re-armouring. This outcome was at least partly the result of the work of the Spunchem technical team: they have looked after the machine in exemplary fashion, adhering to the maintenance intervals and employing uniform feeding. In the final analysis, this approach has also contributed to the problem-free operation

www.spunchem.com

and durability of the machine. The machine’s throughput today is virtually identical with that upon commissioning. The decision to opt for NGR has also paid dividends for other reasons, as it can be demonstrated that the number one premise of putting an economic plant into operation continues to be met. In fact, the S: GRAN 65 still converts up to 180kg of waste into quality granulate hourly on a 7-day, 3-shift basis. Just as impressively, the quality of the recycled material being achieved is outstanding. Lab tests indicate that it would allow the addition of up to 60% re-granulate to new material without any loss of end product or production process quality. As a company with a quality accreditation, however, Spunchem limits the input of

Greater range for electric cars thanks to PC glazing

Is it a tunnel? … With its cavernous entrance, the giant 50m mould looks more like a mechanical whale. The mould halves are opened and rotated by means of hydraulics. Here we see Dr Michael Kast of Isivunguvungu Wind Energy and André Schlenk of Robatech SA, supplier of the Dopag adhesive system which is to be used to join the composite halves

the Isivunguvungu venture, which plans to manufacture about three of the blades a week. About 125 layers of glassﬁbre are used for each half of the blade and laid up in the mould, with the resin then added by vacuum infusion. The halves are then joined with an adhesive supplied via a Dopag dispensing system. Daunting specs are the order of the day here: at maximum rpm, the tip of the blade

will revolve at around 300kph. At optimum performance, each turbine will generate about 2.5 megawatts of power a day. Isivunguvungu operates from a large warehouse in the Cape Town harbour, where it will be supplying the wind energy market from. www.i-wec.co.za

www.gurit.com

THE need to reduce fuel consumption and carbon dioxide emissions is driving the development of alternative drive systems for vehicles. One example is electric mobility, which makes it possible to eliminate the use of fossil fuels all together. One challenge, though, remains the short range of electric vehicles. The key to solving this challenge lies primarily in even lighter weight automobile construction. In this area, Bayer MaterialScience is developing innovative and sustainable material solutions based on polycarbonate and polyurethane for glazing and roof structure, which enable weight reductions of up to 50% compared to existing materials. New design freedoms are being opened up for developing electric vehicles, as fundamentally different concepts can be used for the drive chain. The existing engine compartment in conventional vehicles could thus be dispensed with altogether, allowing completely new vehicle designs. Polycarbonate’s properties allow large, complex moulding of 3D external bodywork parts with integrated elements, such as – and importantly – solar modules. Such technology is especially useful in Africa, where the rate of solar energy is far higher than in Europe. Bayer MaterialScience has developed transparent tinted colours speciﬁcally for PC glazing that ﬁlter out a large proportion of the sun’s infrared (IR) rays. Appropriately treated glazing made of Makrolon® AG2677 enables IR light and energy transmission values for dark colours that are at least as low as commercial thermal insulation pigments for glass. www.bayermaterialscience.com

Turning production scrap into a beneﬁt: The S: GRAN 65 recycling system from NGR has operated 24/7 at Spunchem in Durban for over 10 years

regenerated material to 30 percent. • Spunchem manufactures ‘Spunsulation’ radiant barriers (insulation foils for roofing and walling applications); ‘Energy-Buster’ retrofit roof insulation; industrial fabrics for the automotive (foam laminating, car interior); bedding; construction and mining (backfill); hygiene and medical apparel; and horticultural (weed barrier, crop guard) sectors.

• NEXT GENERATION RECYCLING, BASED IN AUSTRIA, IS REPRESENTED IN SOUTH AFRICA BY TECHNIMAC OF JOHANNESBURG, PHONE 011 882 6630. www.ngr.at www.technimac.co.za

DECEMBER 2011 / JANUARY 2012 7

A roof module with glazing and integrated solar modules developed as a prototype component and concept study by Webasto AG and exhibited in an electric car at the IAA, weighs just 20 kg. The roof module’s low weight is thanks largely to the lightweight panoramic panel. This consists of the transparent polycarbonate Makrolon® AG2677, developed by Bayer MaterialScience for automotive glazing

www.webasto.com

PICTURES COURTESY OF PACKAGING & PRINT MEDIA. PHOTOGRAPHY BY CLIVE GLOVER.

GOLD PACK AWARDS 2011

Gold Pack Awards 2011 Plastics winners do themselves proud Packaging of South Africa’s Gold Pack Awards programme, established in 1974, is entrenched as the premier event for South Africa’s packaging fraternity. This year the programme attracted 133 entries from which the judges selected 37 worthy recipients of the ‘Best in Category’ awards.

FROM PET wine bottles, sleek oval cosmetic tubes, tamper evident caps with extendable pouring spout, 90-degree moveable handles and so much more, the plastics* winners in this year’s prestigious Gold Pack Awards did themselves and the industry proud. Undoubtedly, the Institute of

(plastics* - for the purposes of this article we have only focused on the winners who used plastics in their products or packaging)

Mpact wins overall Gold Pack Trophy Newly listed company walks away with six Gold Medals in total MPACT won the overall Gold Pack Trophy at the prestigious 2011 Institute of Packaging SA (IPSA) Gold Pack Awards, hosted in Cape Town on 25 October for its RAPPET™ 187ml Burgundy wine bottle. The newly listed company also walked away with a total of six Gold Medals for products in various categories. Mpact’s RAPPET 187ml Burgundy wine bottle received the award for the best overall product with the product’s environmental beneﬁts, signiﬁcant cost saving and practical functionality being amongst the features highlighted by the judges. “We are delighted that our product has won the Gold Pack Trophy,” said Bruce Strong, CEO of Mpact. “We are proud that we have been recognised for our quality and innovation through these awards, and we will continue to work closely with our customers to grow their quality brands.” The RAPPET bottle was launched by Cape Classics in 2010 for its Indaba brand used on JetBlue Airways in the United States. The bottle was also awarded ‘Best in Category’ in Beverages. Mpact Plastics also received Gold Medals for: • Preform and Closure Lightweightings for 500ml, 1-litre and 2-litre Carbonated Soft Drinks (CSD) Products (Beverage Category) • Backsberg ‘Tread Lightly’ RAPPET™ wine bottles (Beverage Category) • RAPPET™ Georgian Green wine bottle (Beverage Category) • Poolbrite Month Mate Super Plus Floater (Household Category) Mpact Corrugated won Gold Awards for: • Itacitrus Lime Export Carton (Export Category) • Ice Cream Freezer Transit Pack for Kentucky (Transit & Bulk Packaging Category) The Gold Pack Trophy was awarded to Mpact for its RAPPET™ 187ml Burgundy wine bottle

www.mpact.co.za 8

DECEMBER 2011 / JANUARY 2012

FOOD Nampak Flexibles GOLD L MEDA

Simba Doritas Late Night Chip Pack with AR print technology – Representing a ﬁrst in South Africa’s chip category, the use of AR (Augmented Reality) interactive packaging has brought improved brand recognition and brand awareness. The judges complimented this engaging concept for teenagers, and noted its technological excellence, especially the low-cost simulation of a QR code.

GOLD L MEDA

Parmalat, Polyoak Packaging

Parmalat fresh cream in 250ml in-mould labeled cup with foil seal and overcap – Once opened and the foil seal discarded the cup, IML label and overcap are easily recyclable as all are manufactured from polypropylene. The judges commended the reusable overcap that offers great consumer convenience.

BEVERAGES GOLD L MEDA

ACF Labels: DLC (Afripack), Boxmore Plastics

Coca-Cola range (Coke, Fanta, Sprite, Stoney and Bonaqua) in PET bottles – The judges agreed that the move to thinner-gauge wraparound labels (now 38μm cavitated BOPP) and to lighterweight PET bottles (thanks to the change from the 1810 to 1881 neck ﬁnish) has had a positive environmental impact for the CocaCola soft drink range – without affecting these products’ strong shelf presence.

GOLD L MEDA

Industri-Bott/Industri-Bag 3-Litre I-Tube ‘Bag in Tube’ – With its patented snap-on lid and base, plus a retractable carry handle, this innovative three-litre pack is ideal for the high-quality bulk consumer wine segment. The judges liked the powerful 360-degree graphics.

THE PLASTICS WINNERS!

ELECTRONIC / AUTOMOTIVE

BEST INRY O CATEG

“Best in Category” and Gold Medal awards were presented to the following for products manufactured from plastics.

Pak 2000, JJ Precision Plastics (Astrapak), Sasol Oil

BEVERAGES Gold Medals • ACF Labels: DLC (Afripack), Boxmore Plastics – Coca-Cola Range in PET bottles

Sasol 5-litre lubricant container – The judges were bowled over by this pack’s 90-degree moveable handle, the ﬁrst time a moving handle has been applied to a blow-moulded container. They also applauded the colour-coded grip, the tapered neck and dual tamper-evident colour-coded tapered closures.

• Industri-Bott/Industri-Bag – 3Litre 1-Tube ‘ Bag in Tube’ • Polypet, African Closures (Polyoak Packaging) – 28mm 1881 Gas-Lock Preform and Closure system ELECTRONIC/AUTOMOTIVE Best in Category • Pak 2000, JJ Precision Plastics (Astrapak), Sasol Oil – Sasol 5-Litre Lubricant container

GOLD L MEDA

Pak 2000, JJ Precision Plastics (Astrapak)

Castrol 500ml lubricant bottle – The judges were delighted with the clever design of the tamper-evident cap with its extendable pouring spout and the way in which it retracts into the bottle for reuse.

Gold Medal • Pak 2000, JJ Precision Plastics (Astrapak) – Castrol 500ml Lubricant bottle FOOD Gold Medals • Nampak Flexible, Simba Doritas Late Night Chip Pack with AR Print Technology • Parmalat, Polyoak Packaging – Parmalat Fresh Cream in 250ml in-mould labeled cup with foil seal & overcap HEALTH & BEAUTY Best in Category • Consupaq (Astrapak), Woolworths – Woolworths Oval Tubes

GOLD L MEDA

Mpact Plastics RAPPET wine bottle – Two Backsberg Tread Lightly varietals were the first certified wines to be sold in these stylish lightweight PET bottles. The judges gave the ‘thumbs up’ to their glass-like qualities and other benefits such as unbreakability, safety and convenience.

GOLD L MEDA

Mpact Plastics

Preform and closure lightweighting for 500ml, 1-litre and 2-litre CSD products – Because of the high-volume brands involved in this extensive project, its success has resulted in substantial reductions in PET resin usage and similar major reductions in carbon emissions.

Gold Medals • Unilever SA, ACF Labels: DLC (Afripack), Cinqplast Plastop (Astrapak) – New Lux body wash range • Unilever SA, JJ Precision, Plastop KZN (Astrapak), Spec Tool & Die – Vaseline Petroleium Jelly jars • ACF Labels: DLC (Afripack), Bowler Plastics, Johnson & Johnson – Shower to Shower range of aerosols & roll-ons HOUSEHOLD Best in Category • Tuffy Brands – Tuffy 20m foil in dispenser, 10m Perforated foil, 5m Foil and Clingwrap Gold Medals • T3 Plastic Packaging – Easy Acid 3-litre and 5-litre bottles • Unilever SA, ACF Labels: DLC, Cinqplast Plastop (Astrapak) – Handy Andy bottles • Unilever SA – Sunlight Dishwasher liquid 1,5-litre polypropylene bottle OTHER Best in Category • Cinqplast Plastop (Astrapak) – Cremora Coffee Creamer

GOLD L MEDA

Polypet, African Closures (Polyoak Packaging)

28mm 1881 Gas-Lock preform and closure system – The lightweight 1881 Gas-Lock cap and preform system results in several consumer-convenience features (such as tamper evidence, and easy opening) while using less plastics. The judges noted that the one-piece, liner-less 1881 closure facilitates recycling and is produced using energy-efﬁcient compression moulding.

DECEMBER 2011 / JANUARY 2012 9

PROMOTIONAL, NOVELTY, FAMILY OF PACKS Best in Category (family) • Pak 2000, JJ Precision Plastics (Astrapak), Sasol Oil – Sasol Lubricant range – 5-litre, 1-litre, 500ml & 200ml Gold Medals • Crystalpack, Rap – Bio Sculpture Nail Care Family • Unilever SA – new Lux Beauty Skin Care Family

GOLD PACK AWARDS 2011

HEALTH & BEAUTY BEST INRY O CATEG

Consupaq (Astrapak), Woolworths Woolworths oval tubes – With their wider faces and backs, these oval tubes – a ﬁrst in South Africa – allow improved design opportunities and provide more space than round tubes for consumer information.

Unilever SA, ACF Labels: DLC (Afripack), Cinqplast Plastop (Astrapak) GOLD L MEDA

New Lux Body Wash range – The judges declared this a well-executed pack, and noted the technical challenges overcome by replacing a PVC sleeve with a PET sleeve and shrinking it on to a PP bottle in a radiant heat tunnel, rather than a steam tunnel.

HOUSEHOLD BEST INRY O CATEG

Tuffy Brands

PICTURES COURTESY OF PACKAGING & PRINT MEDIA. PHOTOGRAPHY BY CLIVE GLOVER.

Tuffy 20m foil in dispenser, 10m perforated foil, 5m foil and clingwrap – The judges were very impressed with the development of a reusable PET dispenser for aluminium foil. They also commended the ﬂow-wrapping of foil rolls in BOPP instead of packing them in more expensive cartons with serrated edges.

GOLD L MEDA

Unilever SA, ACF Labels: DLC, Cinqplast Plastop (Astrapak)

Handy Andy bottles – The judges complimented the facelift given to this iconic brand and found the bolder and brighter packaging visually appealing, with its new cap and the indented waistline.

Mpact Plastics

Poolbrite Month Mate Super Plus Floater – The judges applauded the reduction in plastics content, compared with its predecessor. They also remarked positively on the shrink sleeve decoration and the clever adjusting ring at the pack’s base that ensure tablets dissolve regularly.

Unilever SA GOLD L MEDA

Sunlight Dishwasher Liquid 1,5-litre polypropylene bottle – Replacing the previous PVC bottle (being phased out as a Unilever directive), this polypropylene bottle is aesthetically pleasing and warm to the touch. The material change did not required new converting methods or equipment nor alterations to ﬁlling lines.

DECEMBER 2011 / JANUARY 2012

GOLD L MEDA

T3 Plastic Packaging

Easy Acid 3-litre and 5-litre bottles – The anti-glug feature was among this pack’s winning features. The judges also commented favourably on its non-slip handle and the Visi-Stripe window for added consumer convenience.

GOLD L MEDA

Unilever SA, JJ Precision, Plastop KZN (Astrapak), Spec Tool & Die

Vaseline Petroleum Jelly jars – This packaging change for an iconic brand struck a chord with the judges. They liked their modern look and functionality, especially the new ﬂip-top lid; and were impressed that this new design, developed globally, was ﬁrst deployed in South Africa.

ACF Labels: DLC (Afripack), Bowler Plastics, Johnson & Johnson

Shower to Shower range of aerosols and roll-ons – The judges highlighted the co-ordination between the two main packaging suppliers to overcome the technical challenges encountered in the development of this deodorant range where PET shrink sleeves on polypropylene rollon bottles exactly match direct printing on aluminium cans.

PROMOTIONAL, NOVELTY, FAMILY OF PACKS Pak 2000, JJ Precision Plastics (Astrapak), Sasol Oil

BEST INRY O CATEG

Sasol lubricant range – 5-litre, 1-litre, 500ml and 200ml – The judges applauded the way in which the elements in the ﬁve-litre bottle are incorporated into the smaller packs and they particularly mentioned their visual and tactile appeal, plus their strong colours that provide clear brand identiﬁcation.

GOLD L MEDA Y FAMIL

OTHER BEST INRY O CATEG

Cinqplast Plastop (Astrapak)

Cremora Coffee Creamer – This HDPE jar with tamper-evident polypropylene cap and user-friendly tamper-evident spout was a clear winner. The judges were impressed that the spout not only protects the contents but also removes the need for an internal hermetic seal, reducing costs and making the product easier to open and use.

Crystalpack, Rap

Bio Sculpture Nail Care Family – The judges were impressed with these elegant and classy bottles that are truly ﬁt for purpose in a beauty salon environment. They liked the design that follows a constant ﬂow throughout the range.

GOLD L MEDA Y IL M A F

Unilever SA

New Lux Beauty Skin Care Family – The beauty of this family of packs is the way in which the packaging is co-ordinated between the soaps, the body washes and the hand and body lotions.

DECEMBER 2011 / JANUARY 2012 11

Propak Cape packs them in!

PROPAK CAPE 2011

Many exhibitors already signed for Propak Cape 2014 LATEST technologies, developments and a wide range of products and equipment were showcased at the recent Propak Cape 2011 and co-located shows, held at the Cape Town International Conference Centre (CTICC) in Cape Town during October. Visitor numbers increased by almost 7% over 2008 figures with 5 727 visitors attending the shows over the three-day period and pre-registered visitors accounted for almost 35% of the inflow of people. Geographically, just on 20% of visitors were from outside the Western Cape with over half travelling from Gauteng and KwaZulu-Natal in addition to the Free State, Mpumalanga, Eastern Cape, Northern Cape, Limpopo and North West Province. International visitors travelled from Namibia, Malawi, Mozambique, Nigeria, Zimbabwe, Uganda, Botswana, Ghana, Kenya and Libya in addition to the UK, Europe, USA, Brazil and China. AGQPE’s green food packaging range grows AGQPE Food Packaging Systems sells a range of trays, lidding films and packaging machines, but its flagship product is the sustainable Enviropack range of biodegradable and compostable food packaging containers made from a sugar cane base. The Enviropack range is made in China and carries the European accreditation for compostable products. The three existing generic-size ready-meal trays are popular with supermarket chains as there is no need to change their standard machines and moulds. The containers can be used in both conventional and microwave ovens and are also safe for freezing food. www.foodpackagingsystems.com

1. Go green! Michelle Michielin shows off the Enviropack range of biodegradable and compostable food packaging containers. 2. BASF goes big! Sherisha Ramruthan of Lake International Technologies, exclusive distributors of BASF plastic pigments and additives in SA, with Markus Kropp and Peter Pfundtner, business managers for BASF SE’s performance polymers, and Delyce Ririe, sales and industry manager for 12

AGQPE has recently been appointed as the exclusive supplier for Torus Pak in South Africa and launched this concept to the South African market at Propak. Torus Pak is an innovative HMR food packaging system that allows ready meals to be prepared as a producer would want to present them on a plate. The genius of Torus Pak lies in a removable bottom tab that is easily drawn back under the food, and a frame that guides the placement of the food allowing the meal to be perfectly presented on the plate. www.toruspak.com

Marefa launches ‘Generation 3’ filler Paarl-based Marefa International exhibited models of its Generation 3 bottle filling equipment. The company has serviced the filling industry for 12 years and during the last two years has steadily been developing the Generation 3 systems, with its first achievement being the yogurt tub filler. Also of interest on the stand was Marefa’s South African manufactured 8-valve step filler/capper, a little smaller than her bigger sisters, but in no way holding back as far as functionality is concerned. This is the ideal entry level machine as any start-up operation can simply add on and build an entire assembly line as and when budget allows. www.marefa.co.za

Mpact making an impact in collection of recyclables Mpact Plastic Container’s Julian Hendrickse and Penny Berry show off the company’s latest innovation, the 140-litre recycling wheelie bin. The plastic worm farm, also manufactured by Mpact, is 3

BASF in SA. www.basf.co.za 3. Collapsing crates! Chespak’s Granewille de Jongh and Peter Cook with their newest product, the collapsible plastic crate, available in three sizes and are compatible with standard conveyors and standard size pallets. Chespak has ofﬁces in Springs, Durban and Cape Town and manufactures in Gauteng and the Cape. www.chespak.co.za

retailed at Woolworths stores throughout SA (worms not included). Taking its environmental division into leading ranks, Mpact has committed itself to becoming the front runner in the development of smaller waste collection bins. Since the acquisition of Plastic Omnium manufacturing plant in Brits earlier this year, Mpact has extended its product offering and increased output. www.mpact.co.za

Win-Pak’s palletizing products stack up Win-Pak exhibited two exciting palletizing products – Slip-Stop and Grip Sheet. Win-Pak’s Andre Kraukamp explained that Slip-Stop is a biotic and environmentally friendly product for stabilizing pallets loads. The non-toxic, stable and water soluble liquid is sprayed on to small areas on each layer of the load. The bonding force in a horizontal direction has exceptionally high shear strength and the load cannot slip or separate until a vertical force is applied to separate the load. Slip-Stop can be applied manually or with automatic spray equipment. “We’re working a lot with the orange factories in the Tzaneen area. At the moment we’ve got about 40 Slip-Stop machines working there, and have about another 100 on order,” said Kraukamp. Grip Sheet is a stabilizing insert sheet that holds loads in place by increasing the coefﬁcient of friction between the layers on a pallet. It is water repellent and has a low permeability to gases and helps protect products from moisture. Some formats are suitable for direct contact with food products. www.winpak.co.za

4. Paarl-based Marefa International’s Rodney Gertzen (sales consultant, Jhb), Elana le Roux (marketing) and Martin Maree (sales consultant, CT) with their nine-head rotary ﬁller/capper, ideal for any start-up operation 5. Mpact Plastic Container’s Julian Hendrickse and Penny Berry show off the company’s latest innovation, the 140-litre recycling wheelie bin

PROPAK CAPE 2011

BRE showcases unique lightweight insulation BRE Innovations, distributors of Seymour Manufacturing International’s thermal insulation systems. SMI’s ‘Tempro Cold Stop’ curtain is manufactured from a unique lightweight insulation that has exceptional thermal properties, is widely used in food and logistics industries for applications such as chilled and freezer store trolley entry doors, temporary cold rooms, roll cage and pallet covers, ﬂat pack chiller/freezer and curtains for killing bacteria. Tempro products save between 15-30% of the energy needed to run a cold store of freezer. The Tempro Cold Stop curtains boast ﬁve times greater life than regular strip curtains and can be used to make temporary cold storage areas in normal warehousing, as well as pallet and trolley covers. Also on show was the Lock n Pop pallet stabilization system – an innovation that reduces the amount of stretch wrap required for pallet stabilization. www.bre-innovations.co.za

Pouch Dynamics has it in the bag Pouch Dynamics launched the newest bag in its already wide range – the Bottle Bag. According to Pouch’s Cliff Augustyn, the Bottle Bag is a great alternative to 1

Styrolution: new global styrenics supplier

the ‘bag in a box’ and is manufactured in sizes up to 5 litres. Different nozzle sizes can be used, and the actual bag is manufactured in one piece so it can be printed on all sides. It is supplied flat, saving on transport and storage. Another great advantage of the Bottle Bag is that it has a flat base with no rim and is therefore much more stable than other pouch type bags, especially for heavier fills. The Bottle Bags on show were made from laminated PE, but can be tailor-made in almost any material to suit customer needs.

Plastichem to supply range of styrene materials following the formation of venture from styrenic assets of BASF and INEOS groups

www.pouchdynamics.co.za

Polyplank pallets prove popular Polyplank Manufacturing’s pallets, made from recycled plastics, have “taken off like wildﬁre” since they were ﬁrst introduced and were a popular stop for visitors at this year’s Propak Cape. Polyplank also manufactures furniture and DIY components from plastic waste. On the stand, Polyplank’s Jakes Wallage said the pallets had done especially well: “We’ve also experienced a 100% growth year on year for the past four years,” he added.

STYRENE is undisputedly one of the most versatile polymers and two of the top global suppliers – BASF of Germany and INEOS of Switzerland – have put that versatility to the test through the formation of the new business Styrolution. The new entity, which came to existence in October, supplies • styrene monomer (SM) • polystyrene (PS) • acrylonitrile butadiene styrene (ABS) • styrene-butadiene block copolymers

www.polyplank.co.za

PROPAK CAPE 2011 1. Celebrations! – Nampak Inspection & Coding Solutions’ Ken Farrow and Kevin Lewarne were celebrating having sold over 500 of their inkjet and laser videojet batch-coding equipment in one year. Lewarne said that business was up 30% on last year 2. Jonathan Fitzpatrick of Intelligent Inspection Systems demonstrated the company’s Ideal Cap Sorter vision inspection system. The company is a market leader in the plastics packaging sector across

10. Greg Wade and Mark Burn of Air & Vacuum Technologies showed off examples of their vacuum and pressure equipment, widely used in the packaging industry. Air-Vac also supplies a complete range of lab equipment for this sector www.vactech.co.za 11. ‘Plastics for longer life!’ – Igus, an international supplier of plastic bushings, bearings, guides, carriers and – in short- just about every high-wear plastic component to assist with the goods conveying 14

Europe and has installed systems in 27 countries worldwide. According to Fitzpatrick, the company is now looking to grow its South African clientele www.i2systems.co.za 3. Waste not, want not! Jakes Wallage of Polyplank with the company’s pallets made from plastic waste 4. Brian Walker and Khotso Majoe of Westplex, machine vision suppliers and system integrators, highlighted the Cognex machine vision products on

process, exhibited. Here we see Ryan Hancock of Igus SA and visitor Jon Nixon of Igus UK www.igus.co.za 12. Brendan Burns (right) of Burns Machinery hosted Brian McCleary of Pac-Rite of Durban on his stand. Burns Machinery is the SA agent for Hemingstone of Taiwan, one of the top international manufacturers of bag-making machines, with numerous installations in the country. Pac-Rite manufactures plain and printed polyethylene ﬁlms and packaging products

its stand, here verifying 45 barcodes per second and 6 000 parts per minute www.westplex.co.za 5. Andy Pani of HIC Straws bumped into Peter and Jeremy Samson, father-and-son team who earlier this year sold their company Unsgaard + Samson to Cibapac. The business, which had been in operation since 1931, manufactured tray liners, food wraps and ﬂower packaging, among other products. It continues to operate at its premises in Lansdowne, Cape Town

13. Tom Devnarayan of Neu Pack of Durban and his son Rivaaj attended the Cape Town show; Neu Pack is involved in proﬁle extrusion 14. In the bag! Pouch Dynamics’ Cliff Augustyn and Serena Landman showcased the company’s brand new product, the Bottle Bag

New PS entity – Jens Kathmann (second from left), vice-president of the new ABS business Styrolution, with Stuart Gibson (left) of Thread Management Ltd, and Helmut Oellermann and Elana de Goede of Plastichem, its new agent in South Africa, and Delyce Ririe of BASF SA; BASF is one of the founding partners of Styrolution, along with INEOS group

(SBC) • other styrene-based copolymers (SAN, AMSAN, ASA, MABS), and • copolymer blends (ABS/PA, ASA/PA, ASA/PC). With an estimated annual turnover of €6.4-billion (approx R69-bn), Styrolution group operates 17 manufacturing sites in 10 countries (in Germany, Belgium, France, Sweden, Korea, India, Thailand, USA, Canada and Mexico) and employs an estimated 3400 people. With its combined services, Styrolution will be the global leader in the area of styrene monomers, PS and copolymers. Dr Martin Brudermüller, vice-chairman of the board of directors at BASF, said: “From day one Styrolution will be a global leader in its industry with an excellent competitive position. We are convinced that the decision to combine our styrenics activities in a joint venture is the right one.”

Jim Ratcliffe, chairman of INEOS Capital, said: “Styrolution has the people, the products and scale to compete effectively in world markets. Bringing together plant, products and entrepreneurial employees from BASF and INEOS into a new joint venture company with a clear strategy, provides a firm foundation for long-term success and growth.” Application markets Styrenics are mainly used for household and office products, for electrical and communication devices and for packaging. Styrene-based copolymers are thermoplastic resins on the basis of the monomers styrene and acrylonitrile. They are mainly used in the automotive and technical industries as well as for many everyday products. Styrenic materials (specifically PS foam) are also used widely for building insulation, since heating or cooling buildings account

6. Bucket list! – Well, call that a list of features for this impressive bucket. Nicholas Hean of Pail Pac showed the item, one of the Durban-based group’s latest introductions: this is an in-mould labeled container with tamper-evident seal as well as childproof and water-tight lid for pool chemicals supplier HTH 7. Pallet performance – Lomold group showed the performance of its new pallet, moulded in its Lomotex™ long ﬁbre reinforced

15. Keith Ireland and Michael Baker of Peckpak GDK were on their stand, where they showed various blister packaging solutions. Peckpak is involved in contract packaging – using blister and other industrial thermoformed solutions – with the aim of achieving optimal retail visibility for suppliers www.peckpak.co.za 16. Dial ‘m’ for … The two Jo’s – Jo Spohr and Jo Klip – of Maritime Marketing were ready for

for a high percentage of household energy costs. The PS foams help keep interiors cool in hot or warmer in cold periods. Other popular markets are the automotive, toy/sports/leisure and health markets. SA situation Up till now, the BASF styrenic materials have been supplied in South Africa by BASF SA, but with the emergence of the new separate entity, sales of the Styrolution materials will from now be handled in South Africa by Plastichem, with Thread Management taking up responsibility for direct shipments into Africa. Already one of SA’s top polymer suppliers, Plastichem had an existing relationship with BASF to supply a number of the global group’s engineering materials. Success achieved in that area resulted in Plastichem’s appointment as the Styrolution agent. • STYROLUTION IS OWNED ON A 50:50 BASIS BY BASF AND INEOS INDUSTRIES HOLDINGS. ITS HEADQUARTERS ARE IN FRANKFURT/MAIN, GERMANY. www.styrolution.com

thermoplastics. Here we see Wouter du Toit with examples of stacked pallets, in this case with a load of 1250kgs, which resulted in only minimal ﬂex in the bottom pallet 8. Johan Beyers of Filmatic on his company’s stand, where a variety of automated ﬁlling and handling systems for packaging were demonstrated. Filmatic, based in Paarl but selling internationally for more than 20 years, now also supplies turnkey systems for beverage manufacturers,

anything at Propak Cape. This year Maritime didn’t exhibit working machinery, but Spohr was happy to discuss any blow moulding challenge and Klip ready to discuss – well, anything 17. Among the visitors at Propak Cape 2012 were Keith Reading and Bryan Webb of Mouldplas of Johannesburg

including for PET containers, that cover production of preforms and ISBM as well as the downstream processes of ﬁlling, labelling and capping. 9. Winplas team – New on the Winplas team which toured the Cape show was Barry Bekker (centre), who is the now business unit manager for the group’s Cape Town operation. Here we see him with Winplas production director Tony Barao and MD Warwick Oakley www.winplas.co.za

18. Mark Liptrot of Aﬁpack (right) was on the lookout for environmental or recycling opportunities and solutions and was glad to come across Jo Fitzell on the PlasticsSA stand, where he was able to see examples of roof tiles and coat hangers made with mainly recycled grade materials

PROPAK CAPE 2011

West African cruise a welcome breather 1

3 Sunset cruise – West African Group hosted a cruise from the Waterfront on the second night of Propak Cape 2011 and the not insigniﬁcantly sized ‘Sea Princess’ just managed to ﬁt the full complement. Due to some strong winds that evening, the Princess did not tarry out on Table Bay for long and the party in fact continued for longer once the vessel was moored back at the quay (above)

bouts of Tufﬂex Polymers and Kobus Botha of Amec Plastics of George 3. The Metmar/West African Group team were looking good on the cruise! Here we see Tritia du Plessis and Brent Hean (Metmar) with Natalie Conde, Grant Rossetenstein and Margaret Wilson of WAG, all of who had good sea legs on night (not everyone did) 4. Harry Rombouts of Tufﬂex Polymers, which is part of the Metmar group, and Sonja Fourie of Cape Polymers, the Cape distributor for West African Group

1. PSPC gathering – With a number of the Polystyrene Packaging Council’s committee members on the cruise, an ad hoc PSPC meeting was conducted on the ‘Sea Princess’ with Anton Maingard (Mainpak), Ian Edwards (Cibapac), Brent Hean (Metmar/ WAG), Adri Spannenberg (PSPC chairperson) and Ivan Ortlepp (also Cibapac) in businesslike frame of mind www.polystyrenepackaging.co.za 2. Enjoying the cruise – Wang Zhishan of Yili Machinery of Zhangjiagang, China, with Harry Rom-

5. Tony Stopford of Cape Polymers and Brent Hean of Metmar 6. Literally cruising that night were Anton Maingard of Mainpak and Donovan Rayne and Brian McCleary of Pac-Rite of KZN 7. Imvusa – The team from Imvusa Plastics of Atlantis, comprising Kathy and Karel Geduld and their children Carlene and Carlo, enjoyed the cruise. Imvusa is a blow moulding operation that has been steadily increasing volumes since starting production in 2009

PROPAK CAPE 2011 1

1. Familiar faces! Fairpack’s Redewaan and Joe Ryklief with Suraida West were also at Propak Cape 2. Lots of grip and no slip! Anthony Pearse, Frederic Demonfort and Andre Kraukamp on the Winpak stand, very effectively demonstrated the advantages of Grip Sheet and Slip-Stop, two palletizing products 16

3. Koogan Plastics’ Murray Stone and Craig Munday showed off the company’s latest IML (in-mould labelling) and ﬂexible ﬁlm innovations for their range of buckets and paint tins. www.kooganplastics.co.za

4. Innovation’s our game! BRE Innovations’ Tim Forshaw of Cape Town and Dave Louw of Baypac of Port Elizabeth shared a stand on which they demonstrated the ‘Lock n Pop’ pallet stabilizing system, ‘Tempro Cold Stop’ insulation systems and a lot more www.baypac.co.za; www.bre-innovations.co.za

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PROPAK CAPE 2011

Drawtape garbage bag technology comes to SA

Got it taped – Shaughn Hanley of CMD Corporation of the USA was a co-exhibitor on the Adex stand at Propak Cape. Hanley, here with Adex’s Paul Clark, was showing off the latest drawtape technology from CMD, a system which allows for the automated production of drawtape bags. www.cmd-corp.com

NEW technology for the high-speed production of ‘drawtape’ garbage bags is being introduced in South Africa. A bag-making machine from CMD Corporation of the USA, which can produce the large drawtape bags at up to 400 bags a minute, has recently been installed by one of SA’s top converting groups. Paul Clark of Adex, the SA agent for CMD, said the 1270 GDS (‘Global Drawtape System) machine from CMD was one of the most impressive bag-making solutions he’d seen to date. The machine can produce

www.adexplastics.com

both ‘on a reel’ or ‘interleaf’ bags (where the bags are partially overlaid). A single switch is all that’s required to change from one format to the other. CMD has been making bag machines since 1980 and introduced its patented drawtape technology in 1994. The high-speed rotary machine installed in Johannesburg recently features infeed/ outfeed nips for ﬁlm tensioning and motorized lay-on roll (for adjusting ﬁlm tension in the bag machine drum area). • NOTE: DRAWTAPE BAGS ARE ALREADY BEING PRODUCED IN SOUTH AFRICA, BUT FOR SMALLER, BOUTIQUE-TYPE BAGS.

IPSA seminar reveals setting up shop in Africa not for wimps! MUCH has been written about the role of South Africa vis-à-vis the rest of the continent. South Africa occupies a unique position, in a global context, in terms of its access to southern and sub-Saharan Africa, with much of Africa physically far removed from traditional global trade and investment hubs. The rest of Africa is therefore, supposedly, ideally placed to be entered from a South African base. At least, that may the current thinking. To an extent, at least, such perceptions were debunked at an IPSA business breakfast held in conjunction with Propak Cape in Cape Town

Tanzania – Kishan Singh was thanked by IPSA chairman Ingrid Schoeman after his about dealing in Tanzania, which is not always a simple affair

Angola – Erik Smuts, MD of Nampak Bevcan, shared his experience of setting up and commissioning a beverage can manufacturing facility in Angola

on 27 October.The topic of the ‘Into Africa’ seminar was the challenges and rewards of doing business in Africa. Keynote speaker Erik Smuts, MD of Nampak Bevcan, gave an eye-opening account of his experience in setting up and commissioning a beverage can manufacturing facility in Angola. Smuts focused on the beneﬁts and pitfalls of such an investment and gave some valuable insights. Guests at the breakfast were left in do doubt that if they were thinking about investing in countries north of South Africa, they had better be well prepared. Second guest speaker, Kishan Singh shared his knowledge of Tanzania, including an overview of business practices, the country’s economy and packaging industry. The the third and ﬁnal speaker of the morning, Fanie Cronje, who is involved in export to Brazaville in the Democratic Republic of Congo (DRC), shared anecdotes about the pitfalls, corruption, import tariffs and how to use existing distribution structures to deal with a lack of infrastructure in the country.

PROPAK CAPE 2011

1. Sean Varrie of WrapTite Manufacturing, which produces multi-layer cast stretch ﬁlm and food cling ﬁlm in Cape Town, was visited on his stand by his father Tony Varrie of Plasquip, which exhibited alongside. WrapTite recorded an exceptional response at the show, keeping Sean on his feet for three full days! 2. Extender – Mervyn Moodley and the Safrique team used the show to launch, among other developments, the new plastic compound 18

(Polycom), being supplied from their principals (Omega) in India. Here we see Safrique MD Mervyn Moodley with RaviShankar Kannan of Omega and the Safrique marketing team, Llewellyn Moodley, Razina Ramautar and Talia Moodley (logistics). According to Ravi, the Polycom additive not only brings down overall material costs but also allows for easier production, acting as a processing aid for all applications. 3. Work of art! Mervyn and Razina of Safrique produced this clever design

using Polycom pellets and recycled PP material, a creative solution 4. Paul Clark of Adex hosted the visit of Samir Pandya (left) of Pelican Roto Flex of India. Here we see them with Ed Madza of Magiga Holdings of Botswana. Pelican is one of the top manufacturers of printing presses internationally, with many of its machine in operation in SA. At the show, Pelican showed an example of its ‘Soloslit’ slitter-rewinder www.pelican.in

™

Highly versatile ErgoStar can be used for dynamic hotmelt application

PACKING IN ACTION!

Robatech solution for adhesive, EVA, PU and other compounds ONE OF the many interesting displays at Propak Cape was that of the ErgoStar™ new hand applicator exhibited on the Robatech SA stand. The ErgoStar ‘gun’ combines ergonomic design with highest flexibility in the application: all types of hotmelt such, for example, EVA, PUR and adhesive hotmelts or sealing compounds can be applied highly precisely, be it in the form of beads, spirals or sprayed. Nozzles can be exchanged as required and adapted to the specific needs of the application. The ErgoStar works in combination with the well-proven hotmelt applicators of Robatech. The applicator supplies the hand applicator with hotmelt and controls the temperature. Advantages of the unit include: gentle and not tiring on the operator (straining and muscle tensioning prevented); Cool-touch’ handle ensures safety and protection at work; Minimal force is required to actuate the electro-pneumatic release switch. With outstanding insulation properties, the Cool-touch handle (for which a patent application has been lodged) prevents injuries due to burns. The new hand applicator ErgoStar is the synthesis of ergonomic design and flexibility in the application: The handle can be individually adjusted by means of a screw and adjustments can be made within a few seconds. • ROBATECH SOUTH AFRICA: PHONE 021 510 6903. www.robatech.co.za

Plasquip packed a lot of action into its ‘homemade’ stand at Propak Cape and, besides a range of ancillary equipment, exhibited a twin-screw compounding extruder for colour masterbatch. Tony Varrie of Plasquip showed off some of the machine’s features. Although manufacture of colour pellets is a highly specialised area, the ‘dissection’ of the extruder barrel was a new feature at the show and hence attracted quite a bit of attention, possibly from bulk manufacturers.

Top gun – André Schlenk of Robatech SA demonstrated one of its latest dosing units, a highly versatile nozzle which can be utilized for adhesive, hot melt or PU application from virtually any angle. The intelligently designed, snap-ﬁt components belie the unit’s solid construction: it can be used for high-pressure dosing (up to 100 bar) of materials which are difﬁcult to handle, such as adhesives or polyurethanes. André represents Robatech of Switzerland, where the units are manufactured.

Production cell – The Jetmaster machine in operation on the Plasquip stand was used to manufacture microwavable dish lids. Armed with a handling device from Universal Robots, the 228-ton Chen Hsong injection machine could have produced the dishes at a cycle rate of 7 seconds, so the production rate had to be slowed down … to avoid ﬂooding the stand with mouldings! Besides pick-and-place duty, the robot also opened and closed the machine door. The surprising aspect was that all the dishes produced over the 3 days were taken by visitors, so the display must have been popular!

The work station is adapted to optimally meet requirements of the operator and the job on hand, offering the highest ﬂexibility possible (horizontal: top down; bottom up; hand free)

5. Stretching things – Derek Cranston of Technovaa Packaging Innovations, the new stretch ﬁlm manufacturer in Durban, was visited on his stand by the group’s international chairman, Hassan Darvesh of Dubai. Darvesh group plans to invest further in the KZN plant, he conﬁrmed 6. Polyoak is now supplying thermoformed trays to dairies and beverage manufacturers, giving the manufacturers the opportunity

to ﬁll as and when ready. The trays, usually manufactured from polystyrene, are cut into sixpacks and labeled in advance by Polyoak, with the customer then sealing the lids on. Karl Lampbrecht of Polyoak said the new offering had proved very welcome www.polyoak.co.za 7. Cibapac MD Ivan Ortlepp and his team were busy at the show, showing the company’s many and varied ﬁlm and PS foam products

Motan man – Josef Netzer of Motan of Switzerland visited Cape Town for the show, where one of Motan’s ‘Gravicolor’ blending/dosing units was displayed. Motan has become one of the global pace setters in the material moving area 19

Size does matter when talking ﬁbres

The new long-ﬁbre reinforced thermoplastics developed and launched by Lomotex

INDUSTRY NEWS

Lomotek Polymers launches new Lomotex™ material range “These fibres remain long throughout the LOMOTEK POLYMERS, the sales chanmoulding process, tremendously increasing nel for the Lomold Group in South Africa, the tensile strength and impact properties of recently unveiled their new product range the manufactured product. Once moulded, of Lomotex™ long-fibre reinforced thermothese longer fibres form a grid like structure, plastics to a select group of role players virtually unbreakable, making them ideal and decision-makers in South Africa’s for pallets, crates and other heavy-duty plastic industry. plastic products that Lomotek Polymers go through rugged provides powdered The long fibre cycles,” Du Toit said. compounds to thermoplastics are The technology the roto moulding available in sizes between employed to develop industry, where they and manufacture specialize in customer 10 mm and 25 mm and these new generation specific colouring, as are the first of its kind to Lomotex fibres was well as masterbatchbe introduced to SA. developed in-house es and reinforced by Lomotek Polymers, compounds for the which develops and markets technology, injection and compression moulding indusapplication and material solutions. Lomotek tries with production taking place in Elsies Polymers manufactures and sells specialRivier, Cape Town. ized compounds for the rotomoulding, comAccording to Wouter du Toit, marketpression and injection moulding industry. ing and communications manager of the “Because the process enables the usage Lomold Group, these long-fibre thermoof very high performance materials at relaplastics are available in sizes measuring tively low cost, it makes it ideal for use in between 10 mm and 25 mm and are the first of its kind to be introduced to the South the Lomold Pallet – a product that doesn’t just merely match the shape and size of a African market. Willem Louw, Matthias Linder and Zirk du Toit each gave presentations about the new Lomotex polymers at the Lomotex launch on 4 October

The awardwinning, lightweight Lomold pallet which is manufactured using the new, longer and stronger long ﬁbre thermoplastics 20

OCTOBER / NOVEMBER 2011

traditional wooden pallet, but rather incorporates unique features and functionality in a one man lift GMA-specification pallet”, said Du Toit. “Tests have shown that the Lomold Pallet is capable of exceeding the specs of 1 250 kg in dynamic and racking capabilities that a traditional wooden pallet market has benchmarked to be the standard. All of this because of the strength the longer fibres adds to the product properties, while reducing weight to only 8.5 kg (compared to 25-40 kg of a wooden pallet),” he added. Although the Lomold Pallet will be the first and largest application locally using the Lomotex long-fibre reinforced thermoplastics, the product will soon be made available to other plastic manufacturers in selected markets. “We are excited and proud to finally launch Lomotex long-fibre reinforced thermoplastics to the South African market. This product is the result of more than 13 years of research and development and will revolutionize the plastic industry throughout the country and the rest of the African continent,” Du Toit concluded.

www.lomold.com www.lomotek.com

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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 â&#x20AC;&#x201C; wherever it goes, Nissei ASB will be right there at the front continually innovating for tomorrowâ&#x20AC;Ś

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

AfriTrade Call: 076 163 9627 Email: neil@afritradesa.co.za Website: www.afritradesa.co.za Agent in Southern Africa

Ultracool II High Performance Dual Lip Air Ring

EQUIPMENT

Local access to all aspects of ﬁlm production at Indian costs SA PLASTICS spoke to Neil Smith of AfriTrade SA, the agent for Kabra in South Africa.

Over 100 guests, from many of the leading packaging and converting companies in India and elsewhere, saw Kabra Gloucester Engineering of India’s first ‘KAGE’ 5-layer blown film system in operation, producing 2200mm layflat barrier film at 525kg/hour

Kabra Gloucester unveils 5-layer blown film system Outputs of up to 600kg/hour and installed capacity of 4000t/year KABRA GLOUCESTER Engineering of India, a joint venture company with Gloucester Engineering of the USA, unveiled its first ‘KAGE’ 5-layer blown film system at an open house held at the company’s headquarters in Dunetha-Daman in October. Over 100 attendees saw the company’s first fully loaded 5-layer line in operation at Kabra Gloucester’s new facility. KAGE is the brand name for film systems manufactured by Kabra ExtrusionTechnik (KET), using Gloucester Engineering’s engineering designs and technology. The event drew attendees from around the globe, including companies from Africa and Asia. At the open house, the line produced 2200mm layflat barrier film at 525kg/ hour, producing film for oil packaging applications. The line, which can also be used for producing lamination films, is designed for outputs of up to 600kg/hour and has an installed capacity of 4000t/year.

Additional features include: • extruders with light groove feed technology; • 610mm self-centering die utilizing encapsulated feedport technology; • ‘Ultra Cool II’ dual lip air ring with film thickness control utilizing beta gauge measurement; • carbon composite rollers for collapsers; • turret style centre winders. The line has been specifically designed for Prropyl Packs Ltd of Kerala, India, who will use the machine to manufacture film for edible oil packaging applications. The barrier film will not only meet government shipping standards, but will extend the shelf life of the oil, protecting it against oxygen and moisture, and ensuring its cleanliness.

www.kolsite.com www.gloucesterengineering.com

Kabra acquires stake in American company KABRA Extrusiontechnik (KET), the Indian plastic machinery company, has acquired a 15% stake in Gloucester Engineering Co (GEC) of the USA. KET, part of the $120 million Kolsite Group of companies, is India’s largest manufacturer and largest exporter of plastic extrusion equipment, and a leader in the production of pipe, proﬁle & blown ﬁlm machinery. KET commands about 40% market share in its product range in India and has over 8 000 installations in 65 countries worldwide.

SA Plastics: How did you end up representing Kabra in Africa? Neil: Having been involved in pipe and profile production for almost 20 years, I decided to move into machine sales. I looked at several companies before approaching Kabra Extrusiontechnik (KET). Namibian Plastic Convertors, Okahanja Namibia (NPC) were actively looking for new equipment and I saw an opportunity to market KET equipment to them. KET was collaborating at the time with Battenfeld Extrusiontechnik, Germany (BEX) and so we were basically selling BEX equipment at Indian prices. NPC bought a small 45mm HDPE extrusion line and we have continued to grow since. SA Plastics: Kabra has up to now been known in Africa mainly for its pipe extrusion systems. What advantages has its technology offered users? Neil: KET had a collaboration agreement with BEX which it converted to a joint venture in 2006 when BEX bought 14% shares in KET. During this time KET had direct access to the European technology. They used that technology but kept their machines simple to operate which made them ideal for African conditions. With installations in virtually every African country, it proves their simplicity and reliability in production. SA Plastics: How long has Kabra been producing blown film equipment, and how effectively has their technology evolved? Neil: KET started by making film extruders back in the 1960s. They have developed their film blown division independently and developed their technology to suit the needs of their target markets of India, Middle East and Africa. This has resulted in high output machines, based on simple controls and low power consumption. KET equipment has one of the lowest power to output ratios available from any manufacturer. SA Plastics: How can the American connection in the new Kabra-Gloucester entity improve Kabra’s technologies with respect to blown film extrusion? Neil: The new joint venture with GEC brings together western technology with Indian cost effective manufacturing and power efficiency. SA Plastics: SA converters have up until now sourced blown film equipment mainly from Europe and increasingly from China. What advantages will the India-built equipment offer local users? Neil: SA buyers can now get the latest in technology advancements in all aspects of film production at Indian costs, coupled with the high quality of Indian manufacture and power efficiency. There is a direct transfer of technology between the two partners. GEC supply components directly from the USA that are incorporated into overall product to supply a winning combination - the latest technology available with cost effective pricing to a reliable package that will provide constant production for many years.

www.afritradesa.co.za

INDUSTRY NEWS

Brightest star in carbon blacks Transfer of Evonik’s global carbon black business to independent company ALGORAX, the Port Elizabeth carbon black manufacturer, is now known as Orion Engineered Carbons, following the transfer of Evonik’s global carbon black business to a fully independent company, Orion Engineered Carbons. The new company, owned by Rhône Capital and Triton Partners, is the premium supplier of carCarbon Black Pigments are used to provide black colour to many different plastic articles, manufactured by injection moulding, extrusion and other processes

Plastic litter still a problem on our beaches 2011 International Coastal Cleanup shows rise in fast food packaging litter THIS year’s International Coastal Clean-up exposed both the good and the bad – the good being the thousands of volunteers around the country who got involved and made a difference, and the bad being the fact that coastal litter in the form of fastfood packaging is growing at an alarming rate. The audited results of this year’s International Coastal Clean-up Day, which took place on 17 September, show that plastic litter continues to be a problem on South Africa’s beaches. Over the past 26 years, the annual International Coastal Clean-up (ICC) has become the world’s largest volunteer effort for ocean health. This year saw 21 763 volunteers collect a staggering 76 tons of debris from our country’s beaches, 24

DECEMBER 2011 / JANUARY 2012

bon black, generating long-term benefits for stakeholders while remaining committed to responsible business practices with focus on team culture, reliability and sustainability. “We are indeed pleased with the results of this process. Rhône and Triton offer our business the opportunity to meet its full potential with investments in technology and people. Our customers and employees can be confident that we will continue our successful growth as a global leader in carbon black,” said Orion Engineered Carbons chief executive officer Jack Clem. The Port Elizabeth factory is one of 14 Orion production facilities worldwide, focused on ensuring optimum service, product availability and quality to meet the evolving needs and high standards of the tyre, mechanical rubber goods and pigment black markets around the globe. In 2011, Orion’s worldwide production capacity will reach over 1.4 million tons a year. Current local production capacity is over 60 000 tons, with a number of critical grades being manufactured to meet the requirements of the South African market.

The majority of carbon black is sold into the tyre sector, with the balance being sold into the retread and mechanical rubber goods sectors. Pigment blacks are imported mainly from Europe and are sold into the coatings, printing inks, plastics, adhesives and sealants and other specialised markets. The company’s ESHQ Management system complies with the requirements of ISO 14001: 2004, ISO 9001:2008 and Responsible Care. In 2009 the plant was honoured to receive The National Association of Clean Air (NACA) Award in the Industrial Award category, for reducing the impact of airborne pollutants in the Nelson Mandela Bay region. Further accolades were being named a joint winner of the South African Chemical and Allied Industries’ Associations Responsible Care Award for 2010 and being awarded ﬁrst place in the small business category of The Nelson Mandela Bay Business Chamber / SABCOHA Health and Wellness Awards in 2011.

covering a distance of over 1 000 km. Underwater clean ups also took place with the help of 154 divers in the Western Cape who cleared 1 687 kg of debris from the ocean’s ﬂoor. A total of 22% of all the refuse collected from beaches in the Northern, Western and Eastern Cape Provinces were plastic bottle caps (total of 11 202). A total of 7 365 straws or plastic sticks were collected (15%), followed by 7 203 PET beverage bottles (14%). Adding motivation to this year’s International Coastal Clean-up activities, was the fact that Plastics|SA recently became a signatory of the Global Declaration for Solutions on Marine Litter after attending

the 5th Marine Debris Conference held in Honolulu, Hawaii. “We believe that turning the tide on litter is one of the easiest ways to help protect the ocean, and Plastics|SA is now part of an international community of leaders committed to ﬁnding solutions to marine and coastal litter through global cooperation and future partnerships,” said Anton Hanekom, Executive Director of PlasticslSA. For the full report on the 2011 International Coastal Clean-up, visit www.cleanup-sa.co.za/beach.htm • Don’t forget to diarise 15 September 2012 for the next International Coastal Clean-up.

www.orioncarbons.com

This year saw 21 763 volunteers collect a staggering 76 tons of debris from South Africa’s beaches, covering a distance of over 1000 km

www.cleanup-SA.co.za

www.plasticsinfo.co.za

EQUIPMENT 9-layer Evolution® blown ﬁlm line

Reifenhäuser celebrates

100th anniversary

NOW

2010/2011 all-time record year for the company in turnover and orders 1948 The ﬁrst Reifenhäuser extruder

THEN

1986 - Fritz and Hans Reifenhäuser presenting the historical S 60 extruder

IN 1911, locksmith Anton Reifenhäuser founded a small forge in the German town of Troisdorf and laid the cornerstone of Reifenhäuser, a company that ranks among the worldwide leading technology companies in the plastics machinery industry today. This year, the wholly family-owned enterprise celebrates its 100-year history true to its motto ‘Preserving our values. Shaping the future.’ In 1948, sons Hans and Fritz Reifenhäuser started the manufacture of extruders. Development over the following years reflected the typical German economic miracle: Thanks to their entrepreneurial farsightedness, the two brothers were able to turn the forge into a forge of innovations in mechanical engineering. They entered into the plastics industry which was completely new at that time. During the course of a few years they shaped a company that forwarded the extrusion technology in a decisive way. Reifenhäuser laid the foundation for the processing of thermoplastic materials with trendsetting developments and numerous patents. Speaking at the company’s 100th jubilee event at its Troisdorf headquarters on 10 September, chairman Bernd Reifenhäuser said the company had experienced a ‘record year’. He did not reveal specific figures but said 2010/2011 has been an all-time record year for the company in terms of both turnover and incoming orders. During the 2008/2009 recession, the company suffered a large drop in turnover from a record level of €420m to around €315m, excluding Kiefel Extrusion. Guests at the jubilee party were able to view a smith working an original old forge, illustrating the origins of the company when it was founded in 1911. It was not until 1948 that the company

made its first 48GFS30 extruder with a 30mm diameter screw for plastics processing, initially calling it at that time a ‘Schneckenpresse’ (screw press). The company had 50 employees by 1950, when it had achieved turnover of DM 100m (€51m) in production of pipe, blown and cast film lines. Turnover grew to €400m by the time Reifenhäuser acquired Kiefel Extrusion in 2009, which brought an additional €40m turnover to the Reifenhäuser group. From a company to a group of companies: Today, the company is a worldwide active group with six subsidiaries, eight branch offices and over 50 agencies worldwide. The product portfolio includes machines and complete extrusion lines for the production of films, nonwovens, tapes and monofilaments in addition to a 365/24h quality service. More than 80% of these machines and lines are delivered overseas. The company has remained true to its original location until today: It develops and produces in Germany, at its headquarters in Troisdorf and in Worms and Lampertheim - a conscious decision of the Reifenhäuser family. The three brothers Bernd, Klaus and Ulrich Reifenhäuser who manage the family business consider the location in Germany a particular advantage: Here, Reifenhäuser with its more than 1 000 employees concentrates the most comprehensive know-how in plastics extrusion worldwide, in one language at one location. Over the past five years, Reifenhäuser has spent more than €30 million on the expansion of the world’s largest film technology centre and the construction of the world’s largest nonwovens technology centre. 2011 Aerial view of the Troisdorf premises (far left) Various small blown film lines from Polyrema (left)

Massimiliano Marzo (Managing Director of Automa) with Keith Reading

Mouldplas team, Keith Reading, John Davies, Hansie du Preez and Bryan Webb

Italian ﬂair! INDUSTRY NEWS

Mouldplas agents for Automa MOULDPLAS have been awarded the agency for Italian Automa bottle blowing machines in South Africa. Recently Automa launched their new Electro line, including their new Electro AT480DE machine. Automa was founded in 1972 by Vittorio Gentili, a Bologna-based businessman and owner of Panigal, a leading Italian industrial group in the cosmetic, personal care, detergents and food sector. Automa grew gradually, adding to its range of machines and signiﬁcantly increasing its international presence. Automa has been managed by Luca Canossi (Vittorio Gentili’s nephew) after Vittorio’s death in 1988. In 1972 Automa started production of

Afrimold a hit with SA industry AFRIMOLD attracted 84 exhibitors from South Africa, Germany, China and Portugal with more than 2850 visitors to the show at the Sandton Convention Centre from 27-29 September. “AfriMold deﬁnitely reﬂected the buoyancy and pick-up in the economy. We experienced a lot of interest from Asian countries and it was pleasing to note that more than 30% of exhibitors were international companies,” said AfriMold director Ron MacLarty. Ruhla Werkzeugbau based in Seebach, Germany, specialises in complex moulds

continuous extrusion machines, followed 10 years later by a line of ‘speed’ machines. In 1992 the company set up a line of ‘plus’ machines and in 1995 started a PET division. Over the next 14 years Automa has launched a range of machines (APEX, AT300DE, AT950MT, AT500DE). In 2010 the company joined the TMS Group. Why Electro? • Mould dosing system with hydraulic compensator – Automa patented • Carriage shuttle with direct Electro-cilinder (commercial , no gear box) • Hydraulic and electric machines with same operator interface (MMI)

for the medical and cosmetics industries, offering in-mould labelling (IML) and multicavity moulds to the German, Polish and Russian markets. “We see potential in the South African market for our products, particularly the automotive industry, and we have met a lot of new people, obtained good contacts and also had interaction with TASA,” said MD, Marco Schülken. Krugerdorp-based UTP Mould & Die, was at AfriMold for the ﬁrst time. “The show has met our expectations and we’ve made a lot of good contacts with people from the Cape and KwaZulu-Natal,” said UTP manager Kim Eliot. “It has been a good networking experience and has helped us focus on adding value and becoming more competitive.”

Victor Fortune – Gary Grainger showed some of the fast cycling solutions offered by Victor Fortune. Here we see him with Peter Hagan, production manager at The Plastics Factor in Blackheath, Cape Town

www.automaspa.com www.mouldplas.co.za

Chad Haung and Amy Sheh of Pass Card, Taiwan, with Peter Wolber and Sam Maye of PMS Plastics

www.afrimold.co.za

Markus Funk and his wife Kim on the UTP stand – they import high grade specialized steel

See you at AfriMold 2012, from 12-14 July !

SPE IML CIA LIST S Dal Maschio is present in the Italian industrial market since 1829 becoming a brand leader which designs, manufactures and sells robots and automations. In 2009 Dal Maschio Group continues to develop its national and international market share because of the technology innovation and its long established experience. For this reason the Company is able to create standard and special automations to satisfy customer needs. The range of Dal Maschio robots are successfully employed in many fields, for example: automotive, packaging, multimedia, household supplies, gardening and sanitary. Thanks to the energy, the passion and the experience of our staff, we design, create and sell Dal Maschio robots promoting the original “Made in Italy” worldwide.

RETROFITTING - Reconstruction of second-hand robots and out-of-production. • Complete substitution of; numeric control, drives, engines, sped reducer, sliding rails and transmission • Complete rebuilding of electric and pneumatic loop and touch screen controls.

Pecker - two linear plus one rotating pneumatic axis

Technical

Gripper device for 24 insert loading

Customer Care

Purchasing/Spares

Electrically driven rotation

Manufacturing

Side-entry robot for IML applications

CNC

4 Kya Sands Road, Kya Sands • P O Box 960 Northriding 2163 Bryan Webb: Mobile 083 659 3554 • Keith Reading: Mobile 082 458 7579

INDUSTRY NEWS

AS Plastics signs off 160-litre blow moulder for Eskom project AS Plastics Machinery Suppliers’ Bob Austen and son Douglas recently visited China to sign off a 160-litre blow moulding machine at Ziqiang Machinery in Taizhou, China. Bob explained that AS Plastics is currently involved in a project via a company that contracts to Eskom to supply massive plastic ‘bird arresters’ - 10-prong fork-like products used to stop birds from settling on electricity pylons. Bob explained that the prongs are very large and therefore a massive double cavity mould will be used to manufacture them, thus the need for the unusually large 160-litre blow moulding machine. While in China Bob and Douglas visited their existing agencies to renew acquaintances and place orders for machines to insure stock machines are in South Africa by January 2012. • CALL AS PLASTICS MACHINERY SUPPLIERS ON (011) 396 1452 OR 083 679 1159. AS Plastics’ Bob Austen (in the foreground) discusses the machine with Ziqiang Machinery technicians while they ‘dry cycle’ the machine to ensure it performed according to speciﬁcations

Walter and Ricky Hintze ﬂank their daughters, Ingrid Parnell and Marina Cockcroft, who have been working with their parents at Hiwalt in Germiston since completing their studies

Family affair ! Daughters play vital role at Germiston injection, toolmaking business THERE are many family-run businesses in the SA polymer industries, but few company founders have managed to keep their daughters in the company long-term. In the case of Walter Hintze of Hiwalt of Germiston, two of his three daughters have worked with him throughout their careers and continue to perform important roles at the business. Finding roles for family members in manufacturing businesses presents specific problems, not least from the point of view that not everyone can be the boss. At Hiwalt, however, Walter is the managing director while his daughters Marina Cockcroft and Ingrid Parnell are financial manager and operations manager respectively. Established in 1975 by Walter after he emigrated from Austria, Hiwalt is a specialist toolmaking and injection moulding operation. Walter qualified as a master toolmaker in Vienna in 1968 after completing an apprenticeship, and he has continued with the training of toolmakers since, both of staff at Hiwalt and of young aspirant toolmakers as an accredited trainer with the MEIETB. Hiwalt operates nine injection moulding machines with a range of 20 to 260 tons clamp force. It mainly supplies the pharmaceutical industry with containers, closures and measuring cups. Besides that, it manufactures a range of custom products that can be found across a range of industries, from mining to automotive. It also runs an in-house toolroom responsible for in-house maintenance, repairs and the manufacture of new tools. Services offered include wire sparking, spark eroding, CNC milling and CAD/ CAM tool design. • HIWALT, PHONE: 011 873 9055

DECEMBER 2011 / JANUARY 2012

1. Toolmaker Stephen Fox has learned the ropes from Walter, who trained as a toolmaker in Austria in the 1960s. The manufacture of high standard tools is at the heart of Hiwalt’s activities 2. Jabulani Mlangeni, Thato Mokhele and Hazy Magano are the core of the production team at Hiwalt 3. Mabel Nxumalo and Themba Mgcongwane are essential members of the Hiwalt team 4. Apprentice toolmaker Steven Richards working on one of the lathes

INDUSTRY NEWS

Borch team visit Cabletech after exceptional sales Chinese injection machines proving very popular in SA CABLETECH Marketing, a supplier of top-class machinery to the plastics industry, was recently visited by representatives of its principal Borch of China. Sales of Borch’s range of injection moulding machines in South Africa have exceeded expectations over the last year, and the company as a result sent a delegation to visit its SA agent as well as some of the Borchê users in the country. Borch, based in Guangzhou, China, has two manufacturing facilities for injection moulding machines and specializes in the ranges of fully-electric machines in the 30-50 ton range; toggle machines in the 60-1700 ton range; energy saving servo machines, also from 60-1700t; two-platen machines from 900-4500t, multi-component/multi-colour systems from 120-4500t and PET preform machines. Another of Borch’s specialities is its range www.cabletech.co.za

DECEMBER 2011 / JANUARY 2012

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

of machines for polyethylene pipe ﬁttings. These units, in the range 400-2200t, are ideally suited for manufacturers of pipe ﬁttings which require a higher than usual shot weight. The machines offer shot weights of 6 500 to 69 000 grams. Borch was established in 2003. Its production premises in Guangzhou currently cover an area of 180 000m². Its attention to detail, advanced management systems, technical competence and comprehensive customer service have ensured that Borch has become one of the largest manufacturers of precision injection moulding machines and integrated service providers in China. “Borch and Cabletech Marketing share the same core values,” said Cabletech MD Pierre Jurgens. “These values include creating value for our clients, creating value for suppliers, creating value for shareholders, creating value for employees and creating www.borch-machinery.com

value for society.” Besides Borch, Cabletech supplies Liansu extrusion lines for proﬁle and pipe, Kingswell blow moulding machinery, Avian granulation systems as well as a complete range of ancillary equipment, printing solutions, washing and pelletising machines, barrels and screws and many more applications.

Borch visit – The delegation from Borch of China met up with the Cabletech team at the company’s office and warehouse in Kya Sand, Randburg. Eric Morake (spares/showroom), Esmé Jurgens (reception/sales), Isaiah Lesoalo (ancillary sales), Judy Msibi (general office), Joanna Cordy (financial manager), Roxanne Marie (general financial), Marius Hofmeyr (technical manager), Pieter Fourie (service technician), Cherry Liu (overseas sales manager for Borch), Pierre Jurgens (Cabletech MD) and Volcano Zhang (Borch senior technical engineer)

The New Big 5 World class manufacturing

BS Servo Series New generation, energy efficient injection moulder with servo motor.

BH Hybrid Series High speed packaging machine with clamp holding, ideal for in-mould labelling

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BT Toggle Series Low cost high value injection moulding machine

BM Multi-mat Series Multiple injection of up to 4 diffrent colours/materials in a single opperation.

Contact Cabletech Marketing for highly competitive prices. First 5 request for quotations BU Ultra-max Series Two platen series for large products and wall thickness. Cost and space savings up to 4500 ton clamping force

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More high value products at exceptional prices brought to you by For further information contact: Pierre Jurgens: +27 (0) 83 276 1978 Daneil Steenkamp +27 (0) 82 495 2964 dsteenkamp@cabletech.co.za TEL: +27 (0) 11 704 0824

FAX: +27 (0) 11 462 2108

CABLETECH MARKETING E-MAIL: info@cabletech.co.za

WEBSITE: wwww.cabletech.co.za

INDUSTRY NEWS

SABIC celebrates ďŹ rst year in SA with PE seminars SABIC South Africa hosted seminars in Durban and Johannesburg in September, almost exactly a year after the global polymers business had opened its ofďŹ ce in SA. The focus was on blow and injection moulding applications for SABICâ&#x20AC;&#x2122;s range of polyethylene materials, with the speakers being Dr Mohamed Ouddane and Adbulhameed Al-Sheneper. They outlined the advantages offered by SABICâ&#x20AC;&#x2122;s new bimodal products, among other topics. Dr Ouddane, who is based in Canada, has had more than 100 articles published and registered two patents, in the polymer and composites automotive sector. He obtained his masters and PhD degrees in

Canada. He joined SABIC in 2008 as a technical support specialist in the PE group. Topics discussed at the seminar, during which interactive discussion took place, included:

â&#x20AC;˘ additives for PE materials and SABIC grades nomenclature; â&#x20AC;˘ ďŹ lm grades and applications; â&#x20AC;˘ blown ďŹ lm, cast extrusion and bimodal ďŹ lms; â&#x20AC;˘ typical applications and troubleshooting.

www.sabic.com

Dr Mohamed Ouddane (second from right) was the main speaker at the SABIC seminar in Sandton in September. Here we see him with Adbulhameed Al-Sheneper, out from SABIC in Riyadh; Abdullah Sulaim, general manager of SABIC South Africa; and Waseem Abdulla, part of SABIC SAâ&#x20AC;&#x2122;s polymers team

DECEMBER 2011 / JANUARY 2012

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Specialists in Sales, Service & Repairs of a Diverse Range of Injection & Blow Moulding Machines & Auxiliaries

NISSEI

LG Cable

GRAVIMETRIC BLENDING

PARKER

PARTNER FOR THE EXPERTS

BLOW MOULDING

MOULD MAKING PROFESSIONALS

BOE-THERM

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ROBOTICS

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4 Newton Road, Hughes , Ext. 15 Boksburg P O Box 6250, Dunswart 1508 Tel: +27 11 823 5840/41• 823 4952/54 • Fax: +27 11 823 4969 Email: mail@pmsplastics.co.za • www.pmsplastics.co.za

Plastics Institute of Southern Africa

ASSOCIATION NEWS

Material supply: Itâ&#x20AC;&#x2122;s a complex ďŹ eld best left to the specialists Do you need a material distributor? Almost certainly, yes Manuchar presentation â&#x20AC;&#x201C; Ahmet Abdulaziz (centre) of Manuchar following the presentation, with PISA Western Cape chairman Billy MacMillan and Steven Heyman of Manuchar, which sponsored the function

MATERIAL is obviously at the heart of our industry, but itâ&#x20AC;&#x2122;s surprising how many people are unaware about the complexity of procedures involved in securing reliable supply. SigniďŹ cant pressure has come to bear on converters, and hence on suppliers, by the tight supply situation (due at least partly to the increased international demand from China and India) as well as narrow margins resulting from the slow global economic conditions over the last few years. And itâ&#x20AC;&#x2122;s not simply a case of making a call or sending an email for material to be delivered. And the bigger your business becomes, the bigger the material costs, responsibilities â&#x20AC;Ś and pitfalls. With this background, the PISA Western Cape committee decided to invite a speaker 36

from the material supply sector to discuss the topic. Ahmet Abdulaziz of Manuchar SA took up the invitation. A petroleum/ natural gas engineer graduate from the University of Istanbul, Turkey, Ahmet has been involved in polymer supply business for most of his career, ďŹ rst at Petronas (owners of Engen in SA) in Kuala Lumpur and then in Cape Town and Dubai. After a period with SABIC South Africa, he recently joined Manuchar of Belgium, responsible for polymer sales in southern Africa, based in Johannesburg. Manuchar is an international company focusing on distribution of chemicals, steel and polymers with 65 ofďŹ ces in 45 different countries. The ďŹ rst question many converters ask, at least at the outset, is: do we need

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.z 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

a material distributor? Since it is in theory possible to purchase material directly from international suppliers, some converters have taken that course. After that experience, the vast majority opt to use a distributor, who then deals with matters such as letters of credit, bank guarantees, cash in advance and avalized drafts. Besides having, hopefully, an on-going relationship with the material manufacturer, the supplier/ distributor will also take care of issues such as insurance, trans shipment, port delays, tax/duties, delivery and more. By midway through the presentation it had become clear that there was more involved in material procurement than most in the audience had anticipated â&#x20AC;Ś and that was before anything had been mentioned about what happens when things go wrong. Like the converter who had bulk bags delivered, but ďŹ lled with sand! EfďŹ cient material suppliers also offer ďŹ nancial stability, clearing facilities (to deal with the port authorities), local transportation ability and technical assistance. â&#x20AC;˘ THANK YOU TO MANUCHAR FOR SPONSORING THE FUNCTION.

www.manuchar.com

DECEMBER 2011 / JANUARY 2012

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0RESS TOOLS s COMPONENT PRODUCTION SUPPLY s DEEP DRAWING TOOLS s SILICONE MOULDS s AUTOMOTIVE MOULDS s MEDICAL COMPONENT MOULDS s HOUSEWARE MOULDS s 0 % 4 PREFORM MOULDS BLOW MOULDS

#/.4!#4 53 /Fl CE +27 (0)31 765 5720 #HINA -OBILE 0086 151 685 69018 -OBILE +27 (0)82 821 4775 %MAIL brian.miraclemould@gmail.com or brian@miraclemould.com

Generous sponsorship for design competition ONE of the side shows at Afrimold in September was the Pellet Trap Design Competition presented by PISA. The event attracted an array of excellent and innovative entries. Making the competition possible was a generous sponsorship by the PCA to the tune of R30 000. The judges â&#x20AC;&#x201C; A panel of judges like this would have had most of us trembling â&#x20AC;Ś but, no, the men who applied their minds to the pellet trap designs were only concerned with good design. One the panel were Douw Steyn of PlasticsSA (foreground), who came up with the idea for the competition; Jaco Geldenhuys of Nampak Liquid Packaging; Jan Visser of Deter-a-Dye and Terence van der Walt, also of Nampak Liquid, which sponsored the crates on which the entries were displayed at Afrimold The entries of Brandon de Jager and Wessel Wessels were second and third

D TUMBLE ITâ&#x20AC;&#x2122;S ROUGH AN EVENT AT IDWALA MTB

The PISA Western Cape mountain bike â&#x20AC;&#x2DC;championshipsâ&#x20AC;&#x2122; was again a hotly contested event, although prizes were not for athletic performance. Here we see the winners with Nina Dimitru (centre) of Idwala, which sponsored the event: Sean Kierman (Polyoak) got a prize for the â&#x20AC;&#x2DC;most colorful bruisesâ&#x20AC;&#x2122;; Neil Collier (Alplas) for successfully â&#x20AC;&#x2DC;avoiding all single trackâ&#x20AC;&#x2122;; Liza Kruger for being the most professional â&#x20AC;Ś err slowest, and Richard Carter (Mould & Die Solutions) got the prize for the â&#x20AC;&#x2DC;Best nose-diveâ&#x20AC;&#x2122;.

â&#x20AC;&#x2DC;Fire safety of plasticsâ&#x20AC;&#x2122; conference PISA Northern Branchâ&#x20AC;&#x2122;s conference on â&#x20AC;&#x2DC;Fire safety of plastics materialsâ&#x20AC;&#x2122; will take place on Tuesday, 21 February, at Bytes Conference Centre, Midrand. The conference, organised in association with Great Lakes Solutions, among other objectives, aims to â&#x20AC;˘ create awareness of issues surrounding ďŹ re safety of plastic materials; â&#x20AC;˘ summarize the current status of legislation, speciďŹ cations and testing of ďŹ&#x201A;ame retardancy as they pertain to plastic materials in different applications; â&#x20AC;˘ and identify where shortcomings and opportunities exist to improve ďŹ re safety in South Africa, reduce the cost of ďŹ res and reduce loss of life. Some of the topics to be discussed on the day include general ďŹ re statistics,

global trends; applications in building and construction, electrical and electronics, mining, transport and automotive, and packaging; legislation regulations, standards and compliance; additives performance and new developments; and testing methods and certiďŹ cation. Among organisations participating and presenting papers are the Fire Protection Association of South Africa, SABS, Agreâ&#x20AC;&#x2122;ment South Africa, CSIR Fire Lab, CSIR PE, Great Lakes Solution and BASF. â&#x20AC;˘ FOR FURTHER INFO AND TO BOOK, CONTACT ELMARIE BOTHA BY PHONE ON 011 314 4021 OR EMAIL TO: elmarie.botha@plasticssa.co.za

DECEMBER 2011 / JANUARY 2012 37

COST COMPETITIVE ON A GLOBAL SCALE s THIN WALL HIGH PRECISION THROUGH HARDENED MOULDS s YEARS EXPERIENCE s )3/ CERTIl ED TOOL ROOM s )3/ CERTIl ED INJECTION MOULDING AND TESTING FACILITY s /PTIMISED FAST CYCLING MOULDS s #OST EFFECTIVE RAPID PROTOTYPING AND #.# PROTOTYPE MANUFACTURE s l NITE ELEMENT STUDIES UNDERTAKEN

ASSOCIATION NEWS

SAVA takes PVC forward, one sustainable step at a time

Taking ‘em on! – SAVA chief executive Delanie Bezuidenhout was visited on the association’s stand at the Green Building Expo by Adri Spangenberg of the Polystyrene Packaging Council and Gary van Eyk, head of the SAVA management committee. The stand was constructed entirely from and decorated with PVC products, drawing the attention of guests. PVC/vinyl items on show included both the matt and ﬂoor boards, window and furniture proﬁles. Adri’s bag is made from reused PVC fabric 38

THE Southern African Vinyls Association (SAVA) recently began to engage with some of its harshest critics by exhibiting at the Green Building Council of South Africa’s annual ‘Green Building Expo’ in Cape Town in October. The GBCSA event was held at the Cape Town International Convention Centre from 26-28 October. Unsurprisingly, several delegates at the Expo predictably asked ‘What are you doing here?’ Delanie and other SAVA members were able to engage with these delegates and outline the advantages offered by PVC in the building area. “PVC is a chlorinated hydrocarbon polymer that is used by most of us every day. In and around our homes, PVC is used in a wide range of products such as pipes for our fresh water, drainage pipes, ﬂoor coverings, window frames, cabling, toys, pool membranes, kitchen cabinetry, wall cladding, medical drainage tubing and food packaging,” explained Delanie Bezuidenhout, CEO of SAVA. “PVC often comes under attack by environmentalists, architects and speciﬁers for not being environmentally responsible. However, much has changed in the production of PVC and PVC products over the last few years”, she said, adding that PVC has become internationally recognized as a sustainable product and South Africa is set on course to achieve the same result through the committed efforts of SAVA. SAVA has been working tirelessly this past year to develop its ‘Product Stewardship Programme’ (PSP), a series of achievable commitments aimed at addressing the indus-

DECEMBER 2011 / JANUARY 2012

V4XP Unit 2, Greenview Park, 30 Nipper Rd, New Germany, Durban, KZN PO Box 1785, Hillcrest, 3650 Tel: 031 705 7514 or 083 276 0128 Fax: 031 705 8254 Email: martin@mjhsa.co.za

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try’s environmental issues and setting a time frame in which all SAVA members will meet these goals. The PSP aims to bring South Africa in line with the international ‘Best Practice PVC’ standards and commitments for responsible manufacturing and recycling of PVC and PVC products. The PSP is set to be signed at SAVA’s annual general meeting in Johannesburg in February 2012. Objective info about PVC Earlier this year, SAVA also cooperated with the GBCSA in developing a PVC industry questionnaire to obtain further objective information regarding current practices and environmental performances of the local PVC Industry. The GBCSA is assessing the collected data and SAVA expects a positive report back shortly, said Delanie. “Exhibiting and working with the Green Building Council has allowed us to engage with decision makers and role players in the building, engineering and construction industries and to correct the misconceptions or misgivings they may have about the use of PVC”, said Delanie. “We were able to educate them through face-to-face discussions held at our stand, about signiﬁcant inroads that we as an industry have made with regards to the responsible and sustainable use of additives in the manufacturing of vinyl, the recycling of PVC products, increased consumer conﬁdence within the industry and the growing markets for PVC products”, she added. www.savinyls.co.za

Safe motoring and advances in tangential mixing! ‘SAFE Motoring Principals’ and ‘Recent Developments in Tangential Mixing’ were the diverse topics of two recent IOM³ KZN meetings. The decision by the committee to alternate meeting venues between Durban and Pietermaritzburg proved a huge success. Both meetings were very well attended. The 4 October meeting, at the Westville Country Club, saw East Coast Radio’s popular ‘trafﬁc guy’ Johan van Bargen chatting about ‘Safe Motoring Principals’. Although not directly plastic or rubber related, it was a huge success and this was evident by the large turnout. The evening was sponsored by IOM³ and Orchem Trading. The ﬁnal meeting for the year on 3 November, held at the Victoria Country Club in Maritzburg, hosted guest speaker Ian Latchem of Farrell, who discussed ‘Recent Developments in Tangential Mixing’. Latchem has vast experience with Banbury Mixers, having worked in South African for a number of years. He is

now working for Farrell in the UK. Farrel has recently merged with HarburgFreudenberger Maschinenbau GmbH of Germany and, along with its partners Pomini Rubber & Plastics Srl, is offering a unique product range of tangential and intermeshing mixing systems for tyre and technical rubber goods production as well as specialized solutions for silica-based compounding and other reactive processing applications. The evening was jointly sponsored by Farrell and Carst & Walker, the Farrell agent for Southern Africa. The KZN branch annual general meeting is to be held in February 2012 in Durban.

IOM³ KZN chairman Andre Cornelius with Ian Latchem of Farrell. Ian worked in South Africa for a number of year, but is now based in the UK

Institute of Materials: Southern Africa Region

Eastern Cape Deon Riekert p. 041 360 2084 c. 082 940 3109 deon@dschem.co.za

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

National Chairman Hans Strydom p. 011 425 3241 c. 082 449 5920 hans@rubbernano.co.za

Eastern Cape Secretary Diane van Rooyen p. 041 486 1505 c. 083 255 0725 diane@snrubber.co.za

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

www.iom3.org www.iom3.co.za

GREAT EXPECTATIONS! SOUTH Africa plays host to the 17th Conference of the Parties (COP 17) to the United Nations Framework Convention on Climate Change (UNFCCC) in Durban from November 28 to 9 December. PETCO’s Sheryl Ozinsky said a lot is expected from the conference: a new agreement between the developed and developing worlds - basically a plan to save the world. With slow progress having been achieved at previous meetings, expectations are high for the talks to usher in a fair, equitable and binding international agreement to deal decisively with the threat of global climate change. PETCO hosted a talk by Ozinsky in Cape Town and Johannesburg on 31 October and 1 November to discuss ‘Climate change and sustainability in South Africa – what to expect from COP 17’. “The role of the South African government

is key in this. As the host country, all eyes are on South Africa. They are taking up the mantle not only for Africa but, as a leading voice in the global south, they have a grave responsibility,” she said. “What happens in the run-up to this conference and during the conference itself will have long-lasting effects on the entire planet and on the plastics recycling industry too.” Add the Plastic Disclosure Project (PDP) to the equation and one realizes that more and more will be asked of companies in terms of disclosure of their plastic use and their strategies for reducing its environmental impact. The PDP models itself on the Carbon Disclosure Project which has been prodding companies into monitoring and improving their carbon emissions for a decade.

www.petco.co.za

Karen Matthews (environmental co-ordinator, Peninsula Beverages, Coca-Cola), Lynn du Pless (PETCO), Lynn Nathan (Peninsula Beverages, Coca-Cola, procurement manager) and Sheryl Ozinsky (PETCO)

DECEMBER 2011 / JANUARY 2012 39

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PRODUCTS

First all-plastic wheel rim BASF presented the world’s ﬁrst all-plastic wheel rim suitable for high-volume production at Fakuma 2011 in Germany in October. The wheel rim is made from BASF’s Ultramid® Structure, a long ﬁbre reinforced polyamide. Particularly interesting for the automotive sector is the heat-stabilized Ultramid® Endure, especially well-suited for use on turbocharged engines, and Ultrason® E Dimension, a polyether sulfone that combines dimensional stability, stiffness and good processability thanks to a new formulation. www.polyurethanes.basf.de

Winning windows ROPLASTO Systemtechnik GmbH & Co. KG, in Bergisch-Gladbach, Germany, specializing in just-in-time production of complete customized window profile systems, has been operating a twinEX 93-34 D extruder from battenfeld-cincinnati, Bad Oeynhausen/Vienna for about five months. The profile manufacturer was the first company to purchase a twin-screw extruder from battenfeld-cincinnati’s new twinEX series and is very satisfied with its performance. Since its start-up in January, the extruder has been operating in a twin-strand main window profile extrusion line and has been running perfectly, says Romeo Kovac, the company’s MD. Roplasto, which produces a variety of hard PVC profiles for modern building construction on a total of 30 extrusion lines, made a deliberate choice to purchase the twinEX 93-34 D parallel twin-screw extruder. “We really welcomed the merger of Battenfeld with Cincinnati and were eager to see whether the

Roplasto’s range of window profile systems includes 80 mm installation depth for passive houses, plastics profiles which look like aluminium profiles, and various door and window profiles in all colours

new extruder would actually turn out to be a ‘best-of-two’ appliance”, Kovac explains and then adds, “and we have not been disappointed. Especially the extended processing unit, the easy access to all components and the intuitive operation constitute an improvement and have all proved their worth in our daily production.” Roplasto supplies a variety of profiles for all fields of application. The range includes window profile systems with 80 mm installation depth for passive houses, plastics profiles which look like aluminium profiles thanks to an aluminium clip, but have the good insulating properties of plastics, and various door and window profiles in all colours for modernization projects in Eastern and Western Europe. www.roplasto.de www.battenfeld-cincinnati.com

Taking a bite out of dentistry AN increasing number of plastics companies are looking to develop products for the dental market. Amongst them is Dens3000, a Germany-based ﬁrm, which manufactures two-component PMMA teeth for dentures. Dens3000 teeth, which the company says closely resemble natural human teeth in shape and structure, are made by injection moulding biocompatible and monomer-free Densomid modiﬁed PMMA plastic layers - comprising a core material 40

and an outer ‘enamel’ layer - of different hardness and colour. According to patents covering the artificial tooth design, the core material can be a thermoplastic filled with siliceous glass, quartz and hydroxylapatite, as well as injection-mouldable polymer-bound ceramics. Dens3000 says that as the thermoplastic tooth comes directly out of the injection mould and does not require further working, it is highly cost-effective, costing five to ten

DECEMBER 2011 / JANUARY 2012 Dens3000 teeth are made by injection moulding biocompatible and monomer-free Densomid modiﬁed PMMA plastic layers – comprising a core material and an outer ‘enamel’ layer – of different hardness and colour

Clear cups! TURKISH sheet extrusion and thermoforming company, SEM Plastik, is using a newly formulated polypropylene to fulﬁl an important contract for high-clarity, high-stiffness PP cups for milkshakes at a global fast-food company in the country. The improved properties of the material are largely due to the incorporation of Hyperform nucleating agent HPN-600ei into the material. Hyperform Nucleating agent HPN-600ei is a high performance nucleating agent manufactured by additives specialist Milliken & Company. SEM Plastik’s customer had been using imported milkshake cups in 16- and 32-ounce sizes, but was unhappy with the overall quality, especially clarity. SEM Plastik is targeting annual production of around 6.5 million cups. It is also making the domed lids for the cups. By using the new grade, SEM Plastik has

High-speed tubing! HEALTHCARE products leader CR Bard, Inc. recently added two Davis-Standard FPVC high-speed tubing lines to support the company’s growing medical tubing business. A repeat Davis-Standard customer, CR Bard installed the lines in early 2010 at the company’s facility in Nogales, Mexico. The new equipment adds in-house tubing capabilities to support Bard’s extensive line of urological tubing and catheter products. Bard Medical is the market leader in developing and advancing urological drainage technology. “Before this purchase, we had existing Davis-Standard equipment for extruding silicone materials. We’ve been pleased with Davis-Standard’s ability to deliver and

been able to cut the weight of the cups by close to 10% with no loss of mechanical properties. Thermoforming cycle times are believed to be between 8 and 12% lower. PP nucleated with HPN-600ei presents a cost effective alternative to PET and polystyrene (PS). Cups are highly transparent and have an excellent visual appearance, rather than the yellowish appearance that results from the use of sodium benzoate, the conventional nucleating agent in PP. The Hyperform HPN-600ei nucleating agent increases the crystallisation temperature of PP, and allows converters to operate at higher line speeds. They may, in fact, achieve output rates on thermoforming equipment to levels normally only achievable with other plastics. The PP parts can be made with the same wall thickness as other materials. Because the material is less dense, processors use less material, gaining further cost savings. www.milliken.com www.semplastik.com.tr

service turnkey systems. The same is true with this recent purchase,” said Tim Hintze, senior advanced manufacturing engineer at the Nogales facility. “This installation has enabled us to cut costs, improve lead times and better serve customers.” Davis-Standard is a leader in developing equipment that is geared toward commodity-type medical products and catheters with tighter tolerances. Bard’s lines are an example of Davis-Standard’s ability to supply complete medical tubing packages that take the process from start to finish. To support specific processes, DavisStandard’s laboratory line in Pawcatuck, Conn., is equipped to run materials such as FPVC, PEEK, PEBAX, fluoropolymers and other medical grade resins. Bard is currently performing an acceptance run at the lab for an additional silicone extruder.

Milliken nucleating agent helps SEM Plastik win clear cup contract for milkshakes

The new Davis-Standard lines support in-house production of CR Bard’s urological tubing and catheter products

www.crbard.com www.davis-standard.com

Tuffy introduces range of kitchen products times less than artiﬁcial teeth produced by the conventional thermosetting plastic ram extrusion method. The 0.1-0.73g teeth are moulded with 2.5-5.6g shot weights in four 8-cavity moulds, in a cycle time of 22-30 seconds. A full denture set has 28 teeth chosen from 144 samples in 16 different shades, three sizes and various shapes. The teeth are injection moulded on four electric-drive 150-tonne clamping force Arburg Allrounder 520A machines, each equipped with two size 70 injection units.

TUFFY brands have introduced a new range of multipurpose kitchen food products. The new products include zipper bags with Tufﬂock innovation made from 100% recyclable material and clingﬁlm. “We are a brand leader and have been producing kitchen food products for many years but never under our brand name and it is important that the consumer associates our name with quality and affordability,” said Rory Murray, marketing director at Tuffy Brands. “The new packaging allows us to have Tuffy brand visibility and allows our consumers to be brand loyal not just when they purchase refuse bags, but any plastic product.” www.tuffy.co.za DECEMBER 2011 / JANUARY 2012 41

PRODUCTS

Fiat fuel lines age well THE fluid transfer system supplier Hutchinson SRL, of Rivoli, Italy, has specified a DuPont™ Zytel® RS grade based on PA1010 for the production of fuel lines used with both diesel and biodiesel. The renewably-sourced longchain nylon was chosen in preference to competitive grades of PA12 on the basis of its superior temperature resistance and long-term aging performance in biodiesel. The extruded, monolayer fuel line from Hutchinson is already in use on commercial new turbo and multijet diesel engines used on several Fiat vehicles, including the Fiat 500, Panda, Punto, Lancia Delta, Alfa Romeo MiTo and Giulietta. As well as seeking to increase the use of renewably-sourced polymers to reduced dependence on fossil fuels, automotive manufacturers, OEMs and materials suppliers are modifying engine and fuel systems to run efficiently on the latest generation of biofuels, including biodiesel. Components for such systems must resist the chemically-aggressive biofuels, temperature extremes and mechanical stresses for the lifetime of the vehicle.

This specific Zytel® RS grade based on PA1010, which contains more than 60% renewably sourced ingredient by weight, offers properties typical of flexible polyamides with additional benefits such as superior high temperature resistance when compared to materials such as PA 12, high chemical resistance and low permeability to fuel and gases. It is suitable for a range of extrusion applications including fuel lines, hydraulic hoses, corrugated tubes, transmission oil cooler hoses and pneumatic tubes. By specifying the DuPont material for its fuel line for diesel engines, Hutchinson gains a longer-lasting solution that is also market leading in terms of its renewablysourced content. With more than 60% by weight, this Zytel® RS grade based on PA1010 has one of the highest levels

Fuel lines used with both diesel and biodiesel are produced using renewably-sourced DuPont™ Zytel® RS PA1010 by the ﬂuid transfer system supplier Hutchinson SRL of Rivoli, Italy, and debut on all new turbo and multijet diesel engines used on several Fiat vehicles, including the Fiat 500, Panda, Punto, Lancia Delta, Alfa Romeo MiTo and Giulietta

of renewably-sourced content currently available for a high performance nylon. The renewable carbon in PA1010 comes from sebacic acid, which in turn is derived from castor oil.

www.dupont.com

Thermoplastic surgical tray MACPHERSON Medical Inc., an emerging company based in US, has launched a novel multi-purpose surgical instrument tray that is designed to eliminate unnecessary prep time in the operating room. Made of Radel® polyphenylsulfone (PPSU) resin from Solvay Specialty Polymers, the Stat-Mat® Minor surgical tray reduces instrument set-up time from as much as 10 minutes to only 10 seconds, plus it protects instruments from damage and ensures fast and accurate instrument count. MacPherson Medical recently received U.S. Food and Drug 42

DECEMBER 2011 / JANUARY 2012

Administration (FDA) clearance for StatMat Minor which is targeted for general surgery procedures. Radel PPSU is a key element in the functional, userfriendly design. The material is easily formed into complex shapes and offers signiﬁcant manufacturing efﬁciencies versus metal. The surgical tray is designed with an instrument roll and special pockets and holders so instruments stay in place and

avoid damage. This eliminates jumbled piles of instruments and ensures fast and accurate instrument counts. StatMat organizes a complete general minor kit, customizable for multiple procedures. Lightweight Radel PPSU enables the surgical tray to stay under 11 kg, averaging about 6 kg with full instrumentation. The material also offers excellent chemical resistance and withstands repeated disinfection and autoclaving – over 1,000 cycles – while maintaining its toughness and impact resistance.

Made of Radel® polyphenylsulfone (PPSU) resin from Solvay Specialty Polymers, the Stat-Mat® Minor surgical tray reduces instrument set-up time from as much as 10 minutes to only 10 seconds, plus it protects instruments from damage and ensures fast and accurate instrument count

www.macphersonmedical.com

www.solvayspecialtypolymers.com

PLASTICOLORS

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ENVIRONMENT

Plastics and sustainability: Contradiction or precondition?

BASF’s certified compostable plastic and Ecovio® is used in a wide range of applications where biodegradability provides an additional benefit, for example as bags for the separate collection of organic waste and in agricultural applications such as mulch films

Plastics superior in innumerable applications BY 2030, the world’s population is expected to rise to eight billion. Urbanization is increasing, and the trend toward more mobility will continue, with the result that the number of cars worldwide is likely to top two billion by 2030. This challenge leads to a number of questions: What materials can we use to increase energy efﬁciency? How can we cut back on consumption of energy and resources? How can we reduce greenhouse gas emissions? Plastics are among the most important problem solvers in this context because the properties of this class of materials are superior in innumerable applications – from thermal insulation and construction to lightweight automotive components and packaging. In fact, if plastics didn’t exist we would have to invent them to answer the challenges facing society. The paradox The fact that about 90% of all oil is simply burned as fuel or to generate energy is often ignored. Only 5% is used in the production of plastics, which in many applications make a substantial contribution to conserving resources and protecting the climate: They insulate houses, make cars safer and more fuel-efﬁcient, and provide safe and hygienic packaging for food. BASF produces plastics for all these applications – and many others. The production and processing of plastics for a given application often require less energy than alternative materials such as aluminum, steel or glass. And if the entire

lifecycle of plastic products is taken into consideration, another advantage comes to the fore: At disposal, part of the energy can be recovered through incineration, since most plastics contain about as much energy as crude oil. In recent years, the need to conserve fossil resources has resulted in a move toward so-called ‘bioplastics’. But what exactly are bio-based, biodegradable, and oxo-degradable plastics, and are they as environmentally friendly as they are sometimes portrayed? Bioplastics – what are these? Bio-based plastics are plastics based on renewable raw materials such as corn starch or ethanol derived from sugarcane. In spite of their origin, bio-based polymers are not necessarily biodegradable. Other products are advertised as being compostable or biodegradable. They may be based on fossil or renewable resources, or a combination of the two. While there is no clear definition of biodegradability, compostability is defined and regulated by international standards such as EN 13432, ASTM D6400 and GreenPLA. Products certified according to these standards are metabolized by bacteria and converted into water, carbon dioxide and biomass under industrial composting conditions. Oxo-degradable plastics are conventional plastics that contain special additives that cause the plastic to break down into microscopic particles under the influence of heat and sunlight. However, claims that oxodegradables are biodegradable are

misleading since these products do not degrade under composting conditions and do not comply with the standards mentioned above. BASF offers both bio-based and compostable products. The castor oil-based polyol Lupranol® Balance, for example, is a starting material for flexible polyurethane foam used to produce mattresses. The certified compostable plastic Ecovio® is used in a wide range of applications where biodegradability provides an additional benefit, for example as bags for the separate collection of organic waste and in agricultural applications such as mulch films. Whether or not a raw material is truly sustainable depends on a number of factors. In some cases, a fossil-based raw material may have a superior environmental profile compared to a renewable raw material if factors such as land and water use are taken into account. BASF chooses raw materials on a case-by-case basis and always uses them as sparingly and efficiently as possible. In the future, plastics will continue to play a crucial role in ensuring the sustainable development of our society. The trend toward electromobility is just one emerging technology that cannot succeed without innovative plastics. The plastics industry and companies like BASF are called on to develop materials to meet these stringent requirements. This is a challenge that we gladly accept. www.basf.co.za DECEMBER 2011 / JANUARY 2012 45

EQUIPMENT

4-imp. Injection mould made by Glaroform

IML thin-wall technique

Automation Cell with Camera-based QA inspection module for IML processes with separation of nonconforming parts

IML with labels printed on both sides for the perfect decoration of drinking cups SWISS IML (In-Mould-Labelling) specialist Beck Automation AG of Oberengstringen (CH) and Glaroform AG of Näfels (CH) showed thin-walled cups of highly transparent polystyrene decorated on both sides at Fakuma 2011. The Swiss IML experts aim at a cycle of 3.2 seconds with a 4-impression mould running on a Ferromatik Milacron F160. The high speed of the automated equipment is the result of the interaction of a production cell consisting of an injection moulding machine Ferromatik Milacron F160 (Malterdingen/Germany) and an injection mould made by its long-standing partner Glaroform (Näfels/CH). The F160 with its GP (General Performance) 50 plasticizing unit, ﬁlls the 4-impression Glaroform mould with a shot weight of 41 g. Each thin-walled cup has a wall thickness of 0.5 mm and weighs 10.25 g. Glaroform injection moulds are designed by the company’s own well-trained and experienced specialists who pay attention to maximum cooling near the contours to achieve short cycle times. Special tooling steels suitable for high-gloss and high-quality polishing are used for these IML thin-wall applications. The fully balanced and thermally perfectly tuned hot runner system, developed by Glaroform, results in remarkably high shot-weight repetition accuracy. The ‘Swissness’ of the mould is also evident when it comes to

DECEMBER 2011 / JANUARY 2012

details: Attention has been paid to ease of handling and service-friendliness in which low-wear and self-lubricating sliding and guide elements have been used. The Beck automation unit feeds the labels from the label magazines horizontally, inserts them from the side in the cavities and removes the ﬁnished cups from the mould. The system then stacks the cups on a conveyor. Beck Automation has developed a ‘rejects switch’ which can be integrated together with the camera inspection module in or on an IML system. The QA module automatically detects and separates any nonconforming products from the ﬂow of good parts. The advantage of this system is that only the ‘bad part’ has to be separated, and not the complete shot. When necessary the system can easily be changed over to other IML parts or another set.

Optimal ﬁt: perfect labelling of transparent cups

Superfast 3.2 sec cycle: Label feeding and cup removal by Beck Automation

Thin-wall sprinter: Ferromatik Milacron F160

www.beck-automation.com

www.glaroform.ch

www.milacron.com

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EQUIPMENT

Tests up to 500˚C

In the mix! Accurately mixes up to six different materials THE cascade mixing technology used in the new TrueWeigh™ continuous blender from Conair results in a more homogeneous blend, even when additives need to be dosed in very small quantities. This makes the unit ideal for extrusion applications where a highly-accurate blend of sometimes-dissimilar ingredients is critical. The new blenders can be conﬁgured to handle as many as six different components throughput ranges of up to 1365 kg/hr. Ingredient hoppers and dispensing augers can be sized to deliver any amount up to the maximum or as little as 115 gm/ hr with metering accuracy within 0.5% of setpoint, depending on the material. “What makes this gravimetric continuous blender different from batch blenders is that all ingredients are dispensed simultaneously at the desired rate,” explained Alan Landers, product manager. “Different materials ﬂow together out of the blender and into the extruder or a holding bin. In batch blenders, ingredients are dispensed one at a time into a mixing chamber where they are combined by mechanical agitation before being dumped from the blender. This works quite well in applica-

The new continuous Conair blender is part of a growing family of products aimed at meeting the special requirements of extrusion processors making ﬁlm and sheet, pipe and proﬁles, wire and cable

tions involving similar materials (virgin pellets and masterbatch pellets, for instance) and relatively large quantities of minor ingredients. • VIDERCO OF JOHANNESBURG IS THE SA AGENT FOR CONAIR www.conairgroup.com

OFFERING a temperature range from 50° to 500°C, the new Instron-Ceast HDT Vicat 500 AlOxide® thermal tester is setting new standards for the determination of the Vicat softening temperature and heat deflection temperature of plastic materials. Conventional systems typically use silicone oil for heating the specimens. Due to their flash point, these can normally only be used at temperatures up to about 300°C. The new AlOxide tester provides controlled heat input through a fluid bed, consisting of high heat conductivity aluminium oxide powder with a grain size of 20-60μm heated by a flow of hot air. This allows measurements to be performed with highest precision and repeatability even on high-temperature resistant thermoplastics such as liquid crystalline polymers (LCP), PEI or PEEK. Ring tests conducted at an international level have underlined the quality of test results and demonstrated the suitability of the new method for practical use in industrial quality assurance as well as in research and development. The new technology is expected to be incorporated into the relevant testing standards in the near future. The HDT Vicat 500 AlOxide system enables simultaneous testing of three specimens in three independent testing stations. HDT and Vicat tests can be performed in parallel. • INSTRON-CEAST IS REPRESENTED BY ADVANCED LABORATORY SOLUTIONS, PHONE 011 462 1363.

Dreamliner takes to the skies THE Boeing 787 Dreamliner, the world’s first carbon-composite airliner, flew to Hong Kong from Tokyo carrying its first paying passengers in October. With its mostly carbon-composite body, Boeing’s technological flagship offers a 20% improvement in fuel efficiency and a 30% reduction in maintenance costs. Boeing says the jet represents a revolution in air travel. But, unlike Airbus’ giant A380, the 787 is no bigger than many other

conventional aircraft. Boeing’s Scott Fancher said that they had been able to build a plane that could withstand the loads in flight, but that burns 20% less fuel. Critics have raised questions about the safety of carbon fibre in severe turbulence but Boeing dismisses them as ‘nonsense’. The plane was certified by the US Federal Aviation Administration after 20 months of testing.

The newly developed Instron CEAST AlOxide® thermal tester determines the Vicat softening temperature and HDT heat deﬂection temperature of plastics at temperatures up to 500°C

www.instron.de NOTE: The Vicat Softening Temperature (VST) is the temperature at which the surface of a plastic specimen is penetrated to a depth of 1mm by a defined steel needle at a constant load with steadily increasing temperature. The Heat Deflection Temperature (HDT) is the temperature at which a specimen supported at both ends deforms by a specified amount under a defined, centrally applied load and at a uniform temperature increase (outer fibre strain equals 0.2 %).

DECEMBER 2011 / JANUARY 2012 49

EQUIPMENT

‘Famox’ – Fast mould exchange system from Engel Engel extends its product portfolio as system supplier Ready for action in just a few seconds: the new automatic mould changing system sparks productivity boost

a larger range of models is available. A further trend is becoming evident, particularly in the automotive industry: radical reductions in inventories. For injection moulding production, this means ever smaller batches and consequently more frequent mould changing processes. In an effort to avoid a negative impact on productivity or incur an increase in component costs, automatic mould changing systems are becoming increasingly signiﬁcant.

Continuous operating philosophy A uniform operating philosophy, simpler data transfer and a comprehensive security concept are among the advantages of procuring machine and automation Engel famox is equipped with control logic, visualisation from one source. In the and ergonomics of the CC 200 control unit of Engel case of Engel, this stratinjection moulding machines egy now also includes mould changing. Standardised multi-coupling for media lines contribute to the high mould changing speeds of the Engel famox Engel famox is equipped with control logic, visualisation and WITH the aim of further increasing the ergonomics of the CC 200 control unit level of efﬁciency at its customers’ plants, of Engel injection moulding machines. Engel has extended its product portfolio All mould and machine parameters can to include an automatic mould changing be transferred from the machine to the system. Engel ‘famox’ – fast mould exmould changing system without external change – enables mould changes in less interfaces. The diagram of the mould than a minute. changing system can be displayed either Production life cycles are shortened and on the table itself or on the machine. The

The diagram of the mould changing system can be displayed either on the table itself or on the machine

animated screen page gives the user a fast overview of the current status of the system and enables the mould change to be started with only a few settings. Engel famox enables mould changing in less than a minute. Besides the continuous operating philosophy, two further factors contribute to the high mould changing speeds of the Engel famox: the integral mould pre-heating station and standardised multi-coupling for media lines. Direct drive for high availability Whereas conventional mould changing systems work with chain drives, the Engel famox scores points with direct roller drives. Because each roller has its own electric motor, the system proves to be extremely robust in operation. The automatic mould changing system will be available in three sizes. The ﬁrst will be the Engel famox 25 for mould weighing up to 25 tonnes. A version for smaller and larger machines or moulds will follow. • ENGEL IS REPRESENTED BY MARITIME MARKETING www.engelglobal.com

Engel viper range expanded THE successful Engel viper robot was unveiled in a new size at Fakuma 2011. The linear machines are also available with a nominal load-bearing capacity of 90 kilograms. Now available in six sizes (from a nominal load-bearing capacity of 6kg upwards), the linear robots in Engel’s new viper generation are ideally suited to automation tasks in the injection moulding ﬁeld. This means that users of

large-scale machines in the upper clamping force range can also take advantage of the new Engel viper robot. Maximum stability, dynamism and ease of use combined with lightness are the characteristics shared by viper robots in all size groups. An innovative design that utilizes laser-welded steel sections has kept the dead weight of the robots low, enabling the loadbearing capacity to be raised.

www.engelglobal.com 50

DECEMBER 2011 / JANUARY 2012

EQUIPMENT

‘Modular’ 3D printed shoes THE ‘Rapid prototyped shoe’ from avantgarde shoe designer Marloes ten Bhömer hit the spotlight in September as part of an exhibition entitled ‘Power of Making’, at the Victoria and Albert Museum, London. Produced using Objet multi-material 3D printing, the rapid prototyped shoe is designed and manufactured in a modular way so that it can be dismantled and reassembled for the purpose of replacing parts. “The rapid prototyping process stimulated the idea for this shoe. I explored the technology and saw that rapid prototyping – adding material in layers – rather than traditional shoe manufacturing methods, could help me create something entirely new within just a few hours,” said ten Bhömer.

“Objet Connex printers make it possible to print an entire shoe – albeit a concept shoe – including a hard heel and a ﬂexible upper in one build, which just isn’t possible with other 3D printing technologies,” added ten Bhömer. “The shoe is printed as a single entity so the parts come off the printer already assembled, and you can still take the shoe apart later on. It is inspiring and opens up the possibility of interchangeable heels and creating customized designs. Also, the possibility of repairs allows for a more realistic product and changes the idea of rapid prototyping into rapid manufacturing.”

www.objet.com

Shoes, combining rubber-like and rigid materials, created using the Objet Connex 3D printer – the world’s only multi-material 3D printing technology

www.vam.ac.uk/powerofmaking

Separating bio bottles? No problem!

Hagen Award for Kautex Maschinenbau

S+S SEPARATION & Sorting Technology GmbH showed its latest sorting systems for PET recycling at the PETpoint 2011 trade fair in Nuremberg, Germany, in November. S+S has developed solutions that separate contaminants from PET material ﬂows and sorts these material ﬂows into unmixed fractions. More than 80% of the PET recycling companies in Germany, and more than 60% of the European recycling companies use S+S polymer, metal and colour separators for the reliable separation of contaminants. Polymer separators with multi-spectral sensors are used to detect contaminants and plastic types. In PET recycling, these systems separate unwanted plastic types from the PET material based on the infrared absorption of the various plastic types. This is an important sorting criterion against the background of increasing use of ‘bio bottles’ made of up to 100% raw vegetable materials which cannot be distinguished from conventional PET bottles at a glance. Contaminant separators with inductive sensors also remove all metals from mixed PET materials. Optical inspection is performed by high-speed cameras. The optically relevant information is evaluated and the wanted or unwanted colour fractions are separated.

AS EMISSION standards are becoming ever more stringent, tank fittings of plastic fuel tanks are increasingly relocated into the tank interior. A new manufacturing method in extrusion blow moulding has now earned Kautex Maschinenbau GmbH (Bonn) the Dr Reinold Hagen Award 2011. In plastic fuel tanks, the permeation of hydrocarbons through the wall is usually prevented by a special barrier layer as part of a 6-layer coextrusion process. However, if service openings or holes are created subsequently, the barrier layer will be destroyed. Statutory requirements are also becoming more and more demanding. Many efforts are thus focused on integrating the process of fitting interior tank components, such as the fuel pump, directly into the blow moulding process. As an alternative to known methods, Kautex Maschinenbau have developed the so-called C3LS® blow moulding process. The tubular parison is slit open in a longitudinal direction at one point while it is being extruded and is unfolded. With the blow mould partly closed, components such as fuel pump, level indicator, anti-splash baffle, valves and venting conduits can be introduced through the opening created in the parison into the interior of the pre-blown tank bladder.

• S+S SEPARATION IS REPRESENTED IN SOUTH AFRICA BY ENGICON OF JOHANNESBURG.

• KAUTEX IS REPRESENTED BY GREENACRES OF MALMESBURY.

The S+S Flake Puriﬁer performs up to three sorting tasks (plastic types, metal, and colour) in one go

www.sesotec.com

www.pet-recycling.com

DECEMBER 2011 / JANUARY 2012

In the so-called C3LS® blow moulding process, components can be introduced through the opening created in the parison into the interior of the pre-blown tank bladder

www.kautex-group.com

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A-PET

Greenhouses need sun protection too The light stabilizer Tinuvin® XT 200 from BASF prolongs the service life of ﬁlms in agriculture

900 000 tons of greenhouse films produced worldwide in 2009 INCREASINGLY, conventional glass greenhouses are being replaced by greenhouses consisting of simple frames covered with plastic films and combining lower cost with greater flexibility. A total of 900 000 tons of these greenhouse films (usually made from polyethylene, PE for short) were produced worldwide in 2009 - enough to cover about 800 000 hectares, or roughly the entire surface area of the Greek island of Crete, with greenhouses. To make these films resistant to intense sunlight, light stabilizers – of which BASF offers an entire product range under the trade name Tinuvin – are added to the material. The light stabilizers protect the plastic against its worst enemy: weathering from the sun’s intense UV radiation and the heat developing at the contact points with the

metallic greenhouse frame. Besides UV absorbers which directly intercept the harmful radiation in the same way as a sun cream, especially compounds of the sterically hindered amine light stabilizer (HALS) class are important for protecting greenhouse ﬁlms. These HALS slow down not only the weathering process due to UV radiation, but also the degradation of the material caused by heat and chemicals. Because all these trigger factors lead to the formation of free radicals, extremely reactive molecules which destroy the long molecule chains of the polyethylene: the ﬁlm loses its stretch properties, becomes brittle and decays. www.basf.com

Solar shading sophistication to minimize energy usage and carbon footprint. This sustainability strategy includes full-story, vertical solar shading panels using custom-coloured, translucent Lexan Exell D sheet, which flank the windows on the east and west façades. The solar shading panels are fabricated by framing 3.5 m by 5.76 m rectangles of solid Lexan Exell D sheet. They are mounted on either side of the building’s windows on the façades that receive major exposure to sun. Weighing only half as much as glass, Lexan Exell D sheet reduces the amount of material required for structural supports. The PC sheet also provides high impact strength (250 times that of glass) and flame retardance (compliant with the European fire standard EN 13501-1) for safety, and complies with glazing security impact resistance according to Pr EN 356.

High visibility THE new Ultradur® High Gloss B4570 was one of the numerous new engineering resins from BASF which made their appearance at Fakuma 2011 in October in Friedrichshafen, Germany. Compared to existing PBT grades for headlight bezels, this material offers not only high gloss: It is speciﬁcally characterized by its extremely low outgassing at temperatures up to 160°C over an extended period of time. When standard PBT grades that outgas at high temperatures are used for reﬂectors or bezels of especially hot headlights, fogging of the lens may result and reduce the light output of the headlight. With the new Ultradur High Gloss, hardly any outgassing can be detected even at very high temperatures. www.ultradur.com

Bird’s-eye view A NEW application of PC-ABS blends is premiering together with the new Mercedes SLK. The base version of the convertible is equipped with an electrohydraulic vario roof system incorporating 0.8m2 of Bayblend® T85 XF from Bayer MaterialScience. The vario roof collapses fully automatically into the trunk of the Mercedes SLK, transforming it into a convertible in less than 20 seconds. The roof element is coated in the body colour ofﬂine, demonstrates that Bayer’s high-performance material makes it possible to take thermoplastic exterior bodywork parts installed horizontally to an entirely new dimension with respect to size, while still satisfying the very stringent requirements for comfort, optical quality and dimensional accuracy.

MATERIALS

NEW solar shading panels made from lightweight, durable Lexan Exell D polycarbonate (PC) sheet from SABIC’s Innovative Plastics strategic business unit, are making a major contribution to energy efficiency and comfort at the new flagship City of Westminster College in central London. The high-performance panels filter out direct sunlight to minimize solar gain and glare on computer screens. They also admit generous amounts of natural light and are expected to significantly reduce building energy requirements, maintenance and lifespan costs. The distinctive, cantilevered building for City of Westminster College was designed

New low-fogging, high-gloss PBT for headlight bezels

www.bayermaterialscience.com

www.sabic-ip.com The new ﬂagship Paddington Green Campus of City of Westminster College using solar shading panels made with SABIC’s Lexan Exell D PC sheet (PHOTO: ADAM MØRK)

MATERIALS

Record breaking High demands on stone chipping resistance and flange tightness OIL PANS fitted in the 12.8-litre Euro 6 engines for the Mercedes Actros from Daimler are up to 120cm long, 40cm wide and 35cm deep. Probably the largest engine oil pans for trucks to be made of polyamide 6 and 66, they are manufactured by BBP Kunststoffwerk Marbach Baier GmbH of Marbach, Germany, using Durethan from Lanxess. “We used a series of calculations and simulations to confirm the feasibility of the oil pans in advance, thus helping to ensure that the pans could be designed on the computer properly and cost-effectively over a relatively short development period,” explained Frank Krause, an expert for oilcarrying engine parts made of plastic. In this particular application, polyamide offers an alternative to aluminum, sheet steel and sheet moulding compounds (SMC). It produces far lighter components

than die-cast aluminum, for example. What’s more, polyamide components made using injection moulding processes are ready for use straight away. By contrast, die-cast and SMC parts often have to undergo laborious and costly additional processing in order to remove burring, for example. One variant of the oil pan for the 12.8-litre engine is made of the heatstabilized polyamide 66 Durethan AKV 35 H2.0 filled with 35% glass fibres. Another variant is manufactured using the corresponding polyamide 6 grade Durethan BKV 35 EF H2.0. Durethan BKV 35 EF H2.0 offers an additional advantage as its glass fibres are less prominent on the surface. This ensures a high degree of tightness in the groove areas and improved removal from the mould.

No more noise build-up!

The oil pan for the 12.8-litre engine holds 36 litres of oil; it is made of polyamide 66 Durethan AKV35 H2.0

During the development of the oil pans, Lanxess provided its partners with comprehensive support in the form of calculations and simulations. This included structural optimization to improve the acoustic behaviour of the pans, and a simulation exercise to examine resistance to stone chippings and deformation on exposure to sealing force. Simulations were also carried out for the ﬁlling of the injection moulds and the distortion behaviour of the oil pans. www.lanxess.com

www.dupont.com

JUST a small amount of DuPont™ Krytox® high performance lubricant can prevent plastic and rubber components found in the car body and interior from squeaking and creaking. Not only are the oils and greases quick and easy to apply, but they also perform just as well in extreme heat as they do in arctic temperatures – invisibly, without drying out or outgassing and without attacking the plastics and rubber. An example of the efﬁcient use of Krytox is the light guides used in a centre stack control system manufactured by Preh GmbH for two SUVs from a large American automotive OEM. Ahead of assembly at its Mexican facility, the system supplier dips the light guides in a Krytox solution. Following evaporation of the solvent, the remaining, ultra-thin Krytox ﬁlm on the surface of the light

guides prevents noise emissions when driving. The principal components of the so-called ‘centre stack’ control system are formed by the ASA (acrylonitrile-styrene-acrylester) housing and a smoke-grey, translucent console cover which is made of PC and is facing towards the vehicle’s interior. Two light guides, made of PMMA and each with a diameter of approximately 4 mm and 260 mm long, are clipped onto the back of the housing and provide integrated ambient lighting. They are designed in such a way that they emit light along their entire length towards the console. As a result, the entire contour of the insert appears to be spherically illuminated, creating the impression to the vehicle occupants that the centre stack is hovering weightlessly in the console.

During assembly of the centre stack light guides made of PMMA (coloured yellow for identiﬁcation, see arrow) are dipped in a solution based on DuPont’s Krytox® high performance lubricant. As a result, Preh is able to reliably and durably prevent noises emanating from the contact points between the light guides, the ASA housing (coloured blue in the image) and the PC cover (coloured gray) when the car is moving

Innovation shapes the future of tubing POLYVANCED has aligned its tubing technology to permanent innovative change. “Everyone is talking about nanotechnology because in tubing it is a really promising issue for the future”, polyvanced research chemist Andre Epmeier said. “We are not only concerned with surface coatings, but with a complete change in material properties using new nanotechnologies, for example, in the direction of conductivity, permeability or ﬁre inhibition.” Polyvanced offers special environmentally compatible ‘green tubing’ made with a high proportion of

renewable raw materials. Polyvanced CEO Robert Mayr said that additional opportunities are opening up in custom-made tubing and multi-talent tubing, for example, a broad range of ﬂuorine products. Parallel to turnover growth, which doubled in the past year, production is being continuously boosted. The company already produces over 50 million metres of tubing annually and the volume is increasing. The works at Ceská Lípa in the Czech Republic are being expanded with conversion and infrastructure measures to push up output by 60%.

www.polyvanced.com 56

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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Johannesburg: Bill Taylor Jenny Warner Kevin Clark Tel: +2711 489 3600 Fax: +2711 489 3601 Durban: Jaco Smith Ron Dunwoodie Paul Rose Tel: +2731 313 8500 Fax: +2731 313 8518 Website:www.carst.co.za

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MATERIALS

Against the wind BASF’s foam Basotect as sound insulation in wind tunnel at University of Stuttgart THE Institute of Aerodynamics and Gas Dynamics at the University of Stuttgart, Germany can now test components for acoustic emissions. This is possible because soundabsorbing moulded parts made of Basotect®, the melamine resin foam from BASF, have been installed in the institute’s laminar wind tunnel in which model components of aircraft wings or wind turbines are tested. Because of the wind tunnel’s unusual shape the insulation manufacturer made customized Basotect moulded parts for it. Around 45m in length, the wind tunnel sucks in air from the outside and speeds it up at the entry part of the wind tunnel. To improve the quality of the aero-acoustic measuring the wind tunnel had to be additionally sound-insulated. An insulation material was required that combines good sound absorption with high strength and ﬂexible processing capacities – a product

profile that conventional materials have not been able to fulfil so far. Basotect has superb acoustic properties. Due to its open-cell, fine foam structure, it shows very good sound absorption in the medium and high frequency ranges. The good processing capacities of the flame-retardant BASF foam were also crucial in the decision to acoustically retrofit the wind tunnel. The flexible material can easily fit different shapes and is free of fibres when cut. Thus, absorption panels of different thicknesses could be made to fit snugly against the conical walls of the wind tunnel. The Basotect panels used vary in thickness from 3 to 100 cm. They are lined with a thin, black polyurethane skin that protects them from dirt and moisture. www.basotect.com

Electromobility opportunities THE megatrend towards electric and hybrid vehicles is opening up varied and promising areas of application for Durethan polyamides and Pocan polybutylene terephthalates (PBT) from Lanxess. Polyamide and PBT can also be used in place of other materials for non-load-bearing battery components, such as battery covers and power electronic housings. Components like these mostly need to offer protection against electromagnetic radiation and have been made up to now of sheet steel, cast aluminium or sheet mould compounds (SMC) that are metalized or coated with an electrically conductive coating. One alternative is to use highly reinforced, very stiff polyamides and PBT grades that can be vaporized with

aluminium after the injection moulding process – such as Durethan BKV 60 EF or Pocan T7391, which are filled with 60 and 45% glass fibres respectively. These are more costeffective to produce by means of injection moulding, and the resulting components do not require reworking. The metalizing step through vaporization after the injection moulding process can be eliminated if the manufacturer uses electrically conductive polyamide 6, 66 and corresponding blend grades directly. Durethan polyamides filled with carbon fibres promise excellent results. Flame-retardant plug connectors The importance of polyamide and PBT in the production of

plug connectors will continue to rise due to the high voltages and strong currents present in the area of the batteries and drives of electric vehicles. Lanxess’ portfolio includes various materials that are ﬁre-resistant thanks to their halogen-free or halogen-based ﬂame retardance, eg. Durethan AKV 30 FN00. High tracking resistance is just one of the excellent properties exhibited by this polyamide 66.

www.lanxess.com Specially equipped polyamides and PBTs with excellent mechanical and electrical properties are in demand in the manufacture of plug connectors for hybrid and electric vehicles

High-end material under the microscope One hundred years of the synthetic rubber testing centre THE development of synthetic rubbers into a mature material began in mid-1911 with the establishment of the first synthetic rubber testing laboratory at Friedrich Bayer & Co, Wuppertal, Germany. Later it was relocated to Leverkusen and is now a modern service facility where elastomer experts develop top rubber blends for customers around the world. A link was recently established between this institution and its counterpart in Qingdao, China, enabling Lanxess synthetic rubber experts to further shorten the time to market. Lanxess and its application engineers now have virtually instant access to all measurement and analysis results. This means a further reduction in the time customers have to wait to find out whether or not their blend ideas have been successful. One man’s name is closely associated with the foundation of the first ‘rubber testing centre’ in Elberfeld – Dr Kurt Gottlob. Born in 1881, Gottlob had already developed a process for obtaining what was to become a key basic material for synthetic rubber – isoprene – from natural sources such as turpentine oil. Although Fritz Hofmann beat him to developing the first synthetic rubber, his work made him an ideal colleague for Hofmann. Immediately after joining the company, Gottlob set up a rubber testing centre to examine the vulcanization properties of the material samples produced by Hofmann and his team. He discovered that Hofmann’s methyl rubber absorbed less sulfur than natural rubber and vulcanized better in the presence of organic bases – and he is credited with the invention of the first vulcanization accelerator. From 1916, Gottlob’s work gradually moved away from research into basic rubber towards application technology as we know it today. During this time, Gottlob devised instructions and blend formulas to turn the new methyl rubber into useable technical rubber products. Today Lanxess have a portfolio of around 100 000 rubber formulations that can be used for applications of potentially unparalleled diversity and produces an average of 800 rubber blends a month. www.lanxess.com

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Lanxess hits the sweet spot A world first: the manufacture of bio-based EPDM rubber for tyres AT THEIR recent media day in Düsseldorf, chemical specialist Lanxess announced a world first: the manufacture of bio-based EPDM rubber for tyres. Other victories for the environment include continued success in lowering rolling resistance in tyres, and new rubber additives that eliminate, for instance, the need for the heavy metal zinc. “If we could switch the tyres on all the world’s cars overnight to the best materials that are currently available, this alone would save up to 20 billion litres of fuel annually, reducing CO2 emissions by 50 million tons a year,” said Lanxess chairman Dr Axel Heitman. And when Dr Heitman says “the best materials currently available”, he knows what he’s talking about: thanks to groundbreaking research and development, his company is ensuring a greener future. The focus is on using sustainable raw materials as well as on lowering the rolling resistance of tyres. He stressed the importance of ‘green’ tyres. Whereas today around 800 million cars and trucks are to be found on the roads of the world, this figure is set to increase to 3 billion by 2035. The message was clear: increasing mobility is a reality, and it is up to manufacturers like Lanxess to make sure this growth takes place in a sustainable, ecologically sound and socially acceptable way. The roll deal Prompted by environmental concerns and new EU regulations, which call for tyres to be labelled clearly according to level of roll-

ing resistance, Lanxess has put enormous effort into developing a synthetic rubber that offers lower rolling resistance simultaneous with good grip and longevity. The concept of reducing rolling resistance comes down to the flexibility of the rubber. If the rubber is too flexible, it creates more movement in the tyre, which equals friction, and of course friction makes for heat. Thus energy, in the form of heat, is lost through the tyres, instead of being used for forward propulsion. In fact, in regular, inefficient tyres, rolling resistance accounts for 20 to 30% of fuel use. The experts have been hard at work in the field of rolling resistance for years, and Lanxess are confident they’re ready for the November 2012 roll-out of tyre labelling. The colour-coded labelling will alert customers to the eco-friendliness of their tyres at a glance. Though these higherperformance tyres will be more expensive (regardless of manufacturer), what we should be asking ourselves, according to head of technical rubber products Dr Günther Weymans, is not what the price is of these tyres, but what the value is of the protecting our planet. On the additives front, the new silica additive 9202 improves vulcanisation and stiffness while eliminating the need to add the heavy metal zinc, which is yet another boost for the environment. Another product, the hybrid crosslinker Vulcuren works as a stabiliser, contributing to lower rolling resistance in tyres. The Vulkalink group of products similarly cuts rolling resistance as well as improving wet grip.

BY MAYA FOWLER

Sugar, sugar Certainly the biggest announcement of the day was the imminent production of EPDM (ethylene-propylene-diene monomer) from sugar cane-based ethylene – a world ﬁrst! Production is set to be under way in Brazil by the end of this year. The big breakthrough here is that EPDM, for the ﬁrst time, is being made out of an entirely renewable resource. Maize, grain and sugar beet can all be used to this end, but sugar cane is far superior when it comes to reducing emissions, offering a 90% reduction compared to petroleum. Production stands at 7 000 litres of ethylene per hectare. “At the same time,” says Dr Weymans, “the decision in favour of sugar cane does not represent an excessive burden on Brazilian agriculture: less than 1% of the country’s total area, and 1,5% of the area under cultivation is used to grow sugar cane. The process involves dehydrating the ethanol that is derived from Brazilian sugar cane. Braskem SA, a Brazilian company, will supply the bio-based ethylene via pipeline to Lanxess’s plant in Triunfo, Brazil. The eventual product will be known as Keltan Eco, and its uses will go beyond the tyre industry. Says Dr Weymans: “This is our response to an urgent call from you: To increase the eco-friendliness of rubber, not only in the rubber industry, but also for applications in the plastics processing industry, for cable producers and for the building industry.” Tests have shown Keltan Eco to be absolutely on par with conventional ethylene, and, perhaps most importantly of all, take us a step closer to becoming independent of oil. With Lanxess, the word ‘sustainability’ crops up regularly. And now, with the stamp of approval from the Dow Jones Sustainability Index World, it’s clear that this company has put its money where its mouth is. This is in recognition of feats such as lowering climate-related emissions (in Germany) by more than 80%. LANXESS RUBBER MATERIALS SOLD BY PLASTICHEM EPDM (ethylene-propylene-diene) rubber for door seals and windshield wipers – this synthetic rubber does not harden in cold temperatures and is buckle-proof and abrasion-resistant EPDM rubber is ideal for the engine compartment. The material is extremely weather proof and does not become brittle from extreme changes in temperature

www.lanxess.com

COMPOSITES

Arkema acquisition of Cray Valley’s coating & resins business ﬁnal ARKEMA’S acquisition from Total of coatings resins from both Cray Valley and Cook Composites and Polymers, as well as the photocure resins of Sartomer, was ﬁnalized on 1 July. Arkema Emulsion Systems and the coating resins businesses of Cray Valley and Cook Composites and Polymers have combined to become Arkema Coating Resins. Sartomer, also acquired by Arkema, will be operated as a standalone business. Both business units will be part of the Industrial Chemicals division of Arkema. Arkema Coating Resins will be headquartered in Cary, N.C., USA and will maintain operations worldwide, providing customers access to products, R&D resources and sales support spanning many different industry segments. They will offer a wide range

Daniel Souchon, MD of Cray Valley Resins South Africa (2nd from right), ﬂanked by Jean-Luc Beal, MD EMEA Arkema Coating Resins and Daniel Grasset, CEO Cray Valley on the left, and Marc Schuller, Executive Vice President, Arkema. Application has been made to change the name of the company in South Africa. During the interim period, the local company will continue trading as Cray Valley Resins South Africa (Pty) Ltd

of low VOC resin technologies including waterborne, high solids and powder resins along with solvent borne resins and high performance coating additives for formulators of architectural coatings, industrial finishes, construction products, traffic paints, sealants, adhesives, inks, floor care and graphic arts products. In South Africa, Arkema has acquired Cray Valley Resins South Africa (Pty) Ltd. This includes the coatings and the composites business, as well as Harveys Composites (Pty) Ltd. The composites business will oper-

In 2013 BMW will start building the i3 electric car, a vehicle that features a passenger cell made of plastic reinforced with carbon ﬁbre

Race is on to use carbon fibre in a high-volume vehicle BMW plans to begin high-volume production of carbon fibre parts in two years, making it a strong contender to be the first automaker to move beyond limited-edition use of the exotic material. But Daimler, which has taken steps aimed at making carbon fibre parts in 2012, is among the automakers racing toward the same goal. In 2013, BMW will start building the i3 electric car, a vehicle that features a passenger cell – the protective shell around the passenger compartment that ensures the 62

DECEMBER 2011 / JANUARY 2012

integrity of the vehicle in a crash – made of plastic reinforced with carbon fibre. BMW will produce about 30,000 i3s a year, according to Automotive News Europe. Cutting costs In 2010, BMW formed a joint venture with SGL Group of Germany to produce carbon fibre reinforced plastics for electric cars. In the third quarter of this year, a factory in Moses Lake, Wash., will start producing carbon fibre thread, which will be shipped to Germany for conversion into the fabric used

ate with a technical licensing agreement from Total’s composites business, which is being renamed CCP Composites. Application has been made to the relevant authorities (CIPC) for the change of name of the company in South Africa and this will be announced as soon as it becomes effective. During this interim period, the local company will continue trading as Cray Valley Resins South Africa (Pty) Ltd. www.arkema.com

to make parts. To cut costs and allow mass production, the partners are working to perfect a process called resin transfer moulding. The carbon fibre fabric is placed in a mould, and resin is injected under high pressure and temperature. The process, which once took 20 minutes per part, now requires less than 10 minutes. Robots cut and handle the material and components, which previously were made by hand. The robots will help BMW achieved big savings. A pound of carbon fibre now costs only a third as much as a pound used in the M3 CSL coupe’s roof when the limited-edition car was introduced in the 2004 model year. More automation BMW is not the only automaker that plans to use carbon fibre. Last year Daimler announced plans to form a joint venture with Toray Industries Inc., the world’s largest producer of carbon fibre. In January, Daimler said the partners will use carbon fibre and other lightweight materials to reduce the weight of a vehicle’s body-in-white by 10%. Daimler also indicated the partners will produce components for cars to be launched in 2012. Daimler did not indicate which models would feature carbon fibre, but hinted it would use carbon fibre in the vehicle’s passenger cell.

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KZN 031 700 2464 EL

083 282 8850

TECHNICAL

Major order for Motan in Mexico Lego Group cooperating closely with Motan-Colortronic for past 10 years THE Motan-Colortronic group scored the biggest single order in its history when it was awarded a contract by Lego Group for its manufacturing facilities in Monterrey, Mexico: more than 500 ‘Gravicolor’ gravimetric mixing and dosing units and over 1500 ‘Metro’ material loaders. Lego has over 700 injection moulding machines operating at the Monterrey plant. The group manufactures products for the North, Central and South American markets at the plant in the state of Nuevo Léon in Mexico. The factory is in operation 363 days a year. In April 2011, the last instalment of the equipment was delivered comprising of more than 500 ‘Gravicolor’ gravimetric mixing and dosing units and over 1500 ‘Metro’

material loaders. In addition, Motan has installed 24 large external silos mounted on load cells which are linked to 48 fully automatic ‘Metrolink’ material selection and distribution units to feed the raw material to the injection moulding machines. Over 100km of material feed-lines have been installed throughout the system. Material drying is performed with 16 ‘Luxor’ dryers, each with a capacity of 2400m³, and with 104 drying bins. Lego Group has been cooperating closely with Motan-Colortronic for the past 10 years. “We had already completed a project for Lego in their Monterrey plant a year earlier. It was a central raw materials handling system with silos, storage, drying, material conveying and gravimetric dosing for more than 150 injection moulding machines,” said Detlev Schmidt, sales director at MotanColortronic.

Virgin and regrind material is fed to the machines via vacuum operated system, where keeping a balance between the two is necessary 64

The Lego group manufactures products for the North, Central and South American markets at its plant in the state of Nuevo Léon in Mexico (below)

Over 1500 of the Motan ‘Metro HPS’ material loaders are being used, which is a big aid as the plant runs 24 hours a day for 363 days a year (below)

Jes Bladt, senior director and production manager at Lego in Mexico, said the vital prerequisite for the company was “extremely ﬂexible and trouble-free operation, guaranteeing high quality and total reliability.” “We have to be able to totally rely on timely delivery of all bulk raw materials to each one of the injection moulding machines. Here, straightforward and fast material and colour changes are essential. All of the gravimetric mixing and dosing equipment is mounted on movable frames adjacent to the machines, enabling the highest degree of ﬂexibility,” said Bladt. Following a colour/material change, the individual units are cleaned in a separate area, ready to be deployed again. An equally important aspect for Lego Mexico was the level of service offered by Motan. From bases in Monterrey, Mexico City and San Diego (USA), Motan service engineers

are able to be on site at very short notice, round-the-clock 24/7.

Material drying is performed with 16 ‘Luxor’ dryers, each with a capacity of 2400m³ (above)

Vacuum technology To further ensure operational reliability, vacuum technology is used extensively at the plant as well. Each production line (including about 25 injection moulding machines) is supplied with virgin and regrind material through two side channel blowers. The blowers are turned on and off alternately to balance out the operating hours of the individual aggregates. ‘Velocis’ side-channel blowers from Elmo Rietschle are used (Elmo Rietschle is part of Gardner-Denver group). The frequency-controlled blowers (via adjustments in the air volume) allow for a far gentler material conveying. • MOTAN IS REPRESENTED IN SOUTH AFRICA BY PLASQUIP.

More than 500 of the ‘Gravicolor’ gravimetric mixing/dosing units from Motan have been installed at the LEGO plant in Mexico (above)

www.lego.com www.motan-colortronic.com

‘Metrolink’ material selection and distribution units feed the raw material to the injection moulding machines (left)

DECEMBER 2011 / JANUARY 2012 65

TRAINING

KZN companies support Skills Development Learnership programmes become increasingly popular in Durban KZN companies are really supporting Skills Development. This is evident from the number of learners registered on the Learnership programmes over the last few years. In all, 113 individuals have registered on learnerships – either for Plastics Manufacturing or Polymer Composite Fabrication – with Plastics SA (formerly known as the Plastics Federation of South Africa) over the course of this year. “Special mention must be made of the companies who embarked on the Learnership journey with us in 2007 and are still enrolling new learners today,” said Suzanne Stevens, training manager for PlasticsSA in Durban. The top performers from 2007–2011 have been: ITB (Its The Best Manufacturing) of Isithebe, which has enrolled 65 learners; Nampak Megapak, which has sent 59

employees on courses; Fibre-Wound, with 51 enrolled; and Mpact (formerly Mondipak) group, with 19 learners. Each of these companies has individual success stories of learners who have excelled within their respective organisations as a result of their new skills and dedication. To ﬁnd out more about Plastic Manufacturing, Polymer Composite Fabrication or Thermoplastic Fabrication Learnerships, contact your local branch of Plastics SA. East London companies can contact Suzanne at the KZN regional ofﬁce on 031 702 7222. MORE INFO ABOUT THE TRAINING PROGRAMMES IS AVAILABLE AT www.plasticsinfo.co.za

Some of the skills development trainees at their graduation at the training centre in Surprise Road, Pinetown, with PlasticsSA trainer Saki Majwede (left) and KZN training manager Suzanne Stevens (rear)

Graduation caps efforts for Nampak trainees ‘Production is the engine room of any Nampak division’ FRIDAY 12 August marked the proud graduation of several Nampak Megapak and Nampak Liquid students at this year’s Skills Development Graduation ceremony in KZN. In all, 59 students graduated: 23 from Megapak Pinetown and 36 were from Nampak Liquid Westmead. The event was held at the Westville Country Club in Durban. These students completed their studies through the Plastics Federation of South Africa and have qualiﬁed in NQF (National Qualiﬁcation Framework) levels 2, 3 and 4. Each level takes a year to complete. Sandy Gounden, production manager

at Megapak Pinetown, said: “We are investing in our skills base. Production is the engine room of any Nampak division. These graduates run that engine room. They are the future of our business and their training is already bearing fruit”. Well done to Nampak’s KZN regional directors, Dave Tatz and Donald Hicks, for all the support they gave to make the learnership programmes a success in their plants, as well as to the Nampak Rigids HR team for facilitating the process, and to the Nampak graduates for knuckling down and successfully earning their qualiﬁcations. Excitement and joy were in the air on the day as the Nampak students received their certiﬁcates

Environmental auditor, carbon footprint courses CRYSTAL Clear Consulting & Merchants of Johannesburg is presenting a number of environmental and carbon footprinting courses early in 2012. An International Environmental Auditor Course takes place from 20-24 February. This is an IEMA-approved course developed by Aspects International UK and customised for SA Law. It provides the trainee with an International Environmental Auditing qualiﬁcation, an understanding of ISO 14001: 2004, and risk assessments and practical auditing skills. Then, from 6-7 March 2012, an International Carbon Footprint Skills Course will be presented at Carnival City, Gauteng. Creation of awareness, and practical skills in carbon footprint techniques, is vital to every organisation today. This course provides skills for organisations to monitor, measure and minimise their carbon footprint and improve their environmental performance. This two-day programme is aimed at people who want to improve their understanding of carbon footprinting. The course provides practical training in how to calculate and reduce the carbon footprint of your organisation, product or service and achieve environmental improvements and cost savings. For more info, contact 011 524 0661 or email: info@crystalclear.co.za

www.crystalclear.co.za

astics|SA [advert training] 7/18/11 9:00 AM Page 1 C

CY CMY

The refurbishment of the Polymer Science centre at Stellenbosch University, where post-graduate students have been housed since 1970, has been completed

One of the post-graduate polymer science students conducting a test in one of the refurbished laboratories

Polymer Science Building receives facelift

TRAINING

Seminar room at Stellenbosch University named after Ron Sanderson THE Polymer Science Building on the campus of Stellenbosch University has received a much-needed facelift thanks to upgrades, extensions and renovations to the tune of R25 million. The building has housed the Division of Polymer Science of the Department of Chemistry & Polymer Science since the early 1970s, and has over the years had to cope with the increasing demand for post-graduate students and research being done in the ﬁeld. The 13-month building project was funded by Stellenbosch University, with ﬁnancial support being received from the South African Department of Higher Education. It was coordinated by the SU Facilities Management division. Two extensions were added to the

building to include bigger chemical store rooms, more ofﬁce space for students, a recreational area and new laboratory space for the PlasconFreeworld Research Group. The gas, electricity and water supply networks, as well as the air-conditioning and ventilations systems received an overhaul, while all laboratories were refurbished and new fume hoods were installed. The building houses six academics and their research teams, which include more than 35 post-graduate students from honours to post-doctoral level. During the planning process, work space was allocated for 65 post-graduate students. This means that SU is well-prepared for any future growth and developments in

polymer science in the next decade. A new seminar room was named after Prof Ron Sanderson, who for many years was the driving force behind polymer science education and research at the University. SU is still the only South African institution to offer a comprehensive teaching programme in polymer science from BSc Hons to PhD level. Hot topics of research being done by SU polymer scientists include the development of novel polymers for medical applications, the use of polymers in nanotechnology, smart nanoﬁbres, multi-dimensional analytical techniques and polyoleﬁn structure-property correlations. www.sun.ac.za/science

Successful training you can measure PLASTICS processing companies are seeking to use custom-designed programmes to convey business-related information to their staff, and to quantify the effectiveness of these training measures. Engel Austria has come up with two new offers that address this requirement and, at the same time, shed light on the effectiveness of Engel training services. A uniformly high standard of training programmes around the world is guaranteed by a quality assurance system. Year after year, some 3 000 employees from plastics processing firms take part in seminars or workshops at one of Engel’s 14 global training centres. As from this year, participants are being invited to add a final examination to their course. The final examinations are offered for all regular courses around the world. The majority of course participants answer the

DECEMBER 2011 / JANUARY 2012

examination questions online via the Engel e-learning platform, which provides them with an instant written confirmation of their score upon completion. In addition, the Engel training division has responded to customer requests for objective learning feedback with a second new initiative: first Engel gauges the knowledge level of trainees with a competence assessment, then develops custom-made training programmes aimed specifically at them. From basic to expert level, from machine and robot operation to process engineering, Engel covers the full spectrum of knowledge needed by plastics processing businesses – and addresses the individual needs of its clients. www.engelglobal.com

Year after year, some 3 000 employees from plastics processing ﬁrms take part in seminars or workshops at one of Engle’s 14 global training centres Globally certiﬁed quality: the new logo of the Engel training centres

TECHNICAL

Monosandwich: It is some considerable time since the monosandwich method consisted in simply ﬁlling the core of a part with lowcost recycled materials. The use of optionally reinforced or foamed core material gives the part high rigidity and soundand vibration-damping properties. For the skin, visually appealing materials with pleasant tactile properties are available. BY HELMUT KRAFT

Road-ready and sound-insulated THE injection moulding industry is constantly on the look-out for new, sophisticated solutions, analysing existing methods and the polymers used in respect of part properties and technical and ﬁnancial outlay. Often such analysis causes a manufacturing process to be planned again from scratch – as was the case for the stone-chip protection for the VW Amarok. What used to be a straight elastomer part is now a two-component part of PP and TPE made by the monosandwich method (Fig. 1).

Passing the Dakar Rally Endurance Test The new solution, based on a Maxima 650 MSW (Fig. 2, manufacturer: Ferromatik Milacron GmbH), is characterized by improved part properties and by a modified shape which meets the requirements of the distribution of the components. The outer skin of TPE forms a flexible, pliable area, while the PP provides the stone-chip protection in a section of the core with the necessary strength, so that the fixing holes will not tear apart even under maximum load. The fact that the PP remains in the right places in the core is down to the choice of injection point. This combination of PP and TPE for stone-chip protection can be considered a success story as the vast majority of these parts for VW and Audi models are currently produced by the monosandwich method.

Fig 2: The Maxima 650 MSW with 6,500 kN clamping force is equipped with a vertical monosandwich unit (PHOTO: FERROMATIK MILACRON)

Fig 1: The stone-chip protection consists of rigid PP on the inside and TPE outside (PHOTO: SCHÖNEK GMBH & CO. KG)

DECEMBER 2011 / JANUARY 2012

The first injection moulded parts passed the endurance test that is the Dakar Rally (formerly Paris–Dakar): surviving two weeks of gravel roads and desert sand under extreme driving conditions with flying colours. Cold runner technology is the only limitation In the process which Ferromatik Milacron developed back in the 1990s, a standard injection moulding machine is fitted with a secondary extruder, either vertically or horizontally in an L position. First, the core component is plasticized in the injection unit, and then the secondary extruder meters the skin component into the space in front of the screw. The melt flows through the nozzle of the extruder in front of the closed non-return valve of the main unit and forces the already plasticized core melt

The stone-chip protection of the VW Amarok escort vehicle on the Dakar Rally is a monosandwich part (PHOTO: VW)

and the screw back against an adjustable back pressure until the set metering stroke (or shot weight) has been reached. The materials contained in the barrel do not mix, but rather are stored physically one behind the other in the space in front of the screw (Fig. 3). What makes this process so impressive and yet deceptively simple are the two metering strokes for the core and the skin components. This is the only difference between the settings of the monosandwich and the standard injection moulding machine. Injection speed, time, pressure and holding pressure are just the same as for conventional one-component injection moulding. Since the two materials lie one behind the other in the injection barrel, they necessarily ﬂow successively into the cavity during injection. Thanks to frontal ﬂow, the

first melt to enter is pressed against the outer wall to form the skin component, while the subsequent second component acts as the fluid centre and thus the core of the moulded part. Generally, the only requirement for sandwich injection moulding is the use of a mould equipped with cold runner technology. Any experienced injection moulder can set a monosandwich machine and will usually start with a ratio of 40% core component to 60% outer skin. The outcome is examined and the proportion of core component is varied until it is visible at the end of the flow path. Frequently, this proportion lies between 35% and 50% of the shot volume. There are no restrictions on the wall thicknesses which can be injected, because the monosandwich method differs from standard injection moulding only in plasticizing. Injection and holding pressure process remain largely untouched. Good results have been obtained for cups with a wall thickness of 0.8 mm, as well as for automotive parts 2.2 mm thick, or thick-wall handles, or shower heads with walls up to 20 mm thick. Improved flexural strength combined with high optical quality A monosandwich application of a highly stable handle (Fig. 4) has replaced the existing two-component version of the part. The outer skin of ASA complies with medical requirements on cleaning, disinfection, feel, colour fastness and gloss. The required flexural strength was conferred by the core material, an ABS containing 30% glass fibre. In the predecessor two-component part, expensive, stable mould cores had to be used to hold the glass fibre-reinforced preform in the centre. The cores were pulled during over-moulding, but they left behind surface marks. The monosandwich method yields a glass fibre core without mould-holder functions and thus a flawless skin with no marks – reliably and less expensively than the two-component method. A high quality and visually appealing chair body of PP is also produced by the monosandwich method. The required aesthet-

Fig 5: The seat of the chair is reinforced with 40% glass ﬁber. The seat shell in the middle was not colored, so that the core component is visible (PHOTO: KRAFT/OWI GMBH)

ics and tactile properties are achieved by introducing a PP containing 40% glass fibre as core material into the centre of the plastic seat shell (Fig. 5). The part is gated with a sprue gate – the resulting core distribution meets all the designer’s wishes and the technical demands, too. The high flexural strength reaches a maximum in the centre while the softer range of the PP is retained at the corners. In the monosandwich method, this glass fibre material always remains in the plastic centre and does not migrate to the surface. The use of a glass fibre-reinforced core material can lower the total wall thickness in many cases and therefore almost incidentally cut material consumption. Silent, well-shielded parts Improving the acoustic or electrical shielding of injection moulded parts is a technically demanding application. A soft TPE material in the core reduces propagation of sound waves, making the unloved resonance body associated with plastic housings now a thing of the past. Candidate applications are all types of upper and lower housing parts that cover a noisy engine or a noisy transmission. Even in the case of a complex part, a three-plate mould with cold runner point gating at the important places can be used to inject a soft material into the centre.

Fig 3: The melt for the skin component ﬂows from the secondary extruder in front of the closed non-return valve of the main unit and presses the already plasticized core component and the screw against an adjustable back pressure until the set metering stroke has been achieved (GRAPHIC: FERROMATIK MILACRON)

Fig 4: This handle owes its stability to a glass ﬁberreinforced core under an outer skin of ASA (PHOTO: DECEMBER 2011 / JANUARY 2012 71 WEBER WERKZEUGBAU)

TECHNICAL

Fig 6: The housing parts for transmissions include a soft TPE core for noise insulation

Fig 7: Secondary cavities allow the core component to ﬂow into the intended cavity area (PHOTO: KRAFT)

Fig 8: The interior of the part is rendered visible by non-destructive computer tomography and the entire volume of the core component is reproduced as a 3-D body (PHOTOS: SCAN-TEC)

(PHOTO: KRAFT)

Typical applications include engine covers and housings for electric drives (Fig. 6), conceivable for windshield wipers, power windows and electric seat adjusters. If an electrically conductive material or so-called ferroelectric compound such as a steel-fibre-filled plastic serves as the core component, the result is a plastic part with a very good surface combined with strong electrical shielding. Using valuable regrind, saving on virgin resin A common application of the monosandwich method is the injection of regrind to act as core material. In many cases, scrap plastic and sprues are ground in the workshop and added in a certain percentage to virgin resin or sold at a good price on the market. When mixing regrind, there is always the risk that insufficient drying may give rise to streaks on the surface or to visible contaminants. The monosandwich method is the best way to process regrind because it transports any possibly slightly contaminated plastic into the centre of the plastic part while still yielding a perfect outer skin of virgin material. This processing method can be employed in almost every injection moulding shop; all it takes is for those in charge to muster the will and patience to find a suitable part. Every company has an obligation to be sparing with expensive polymer and to seek ways to put regrind to good use. The cost savings that can be achieved can either be passed on to customers or will increase the profits of the injection moulding shop. Often the question arises as to the strength or stability of monosandwich components. Here, studies[1] have shown that the tensile, notched impact and flexural strengths lie mid-way between those of the two materials used, i.e. with allowance for the resulting wall thicknesses of 72

DECEMBER 2011 / JANUARY 2012

core material and outer skin, the technical data from data sheets can be used. Reproducing complex geometries Distribution of the frontal flow of polymer in the cavity varies with wall thickness. To an extent depending on the flow properties of the skin and core component, injection moulding offers little scope for influencing the distribution of the shell or core. The only way to change the outcome is to vary the injection speed and melt temperature. However, if the core component must be positioned in a specific position, setting small secondary cavities yields good results (Fig. 7). Fasteners, eyelets, mounting points and weld lines can be influenced and strengthened in this way. The secondary cavity is connected to a pin gate and falls off by itself during demoulding or, in the case of a thicker gate, is separated by the robot gripper as the moulded part is being demoulded. If the core component contains a chemical blowing agent, this expands while the plastic centre is cooling and presses the outer skin completely against the mould surface. The outer skin stays free of streaks, and sink marks are avoided. One example of this is a shower head. This thick-walled part has a beautiful surface with no sink marks and can be galvanized or painted easily. Quality control with computer tomography Standard quality control for monosandwich parts is exactly the same as for one-component processes, i.e. the surface quality and overall dimensions of the plastic part are examined with tactile measuring instruments. A more recent method is non-destructive examination of the core component by computer tomography. During ongoing series production, the interior of the moulded part cannot be measured

without destruction of the part. Provided that different materials of different densities are employed, computer tomography can detect the core component non-destructively in the 1/100 mm range. Studies of this kind are conducted, for example, by scan-tec GmbH in Rosstal, Germany. The CT scanner (type: Metrotom, manufactured by Carl Zeiss Industrielle Messtechnik GmbH, Oberkochen, Germany) employs a micro-focus X-ray tube which continuously irradiates the rotating specimen. The reconstruction software converts the images on the detector into a 3-D data model. This allows the wall thickness of skin and core materials to be presented in the round and reliable quality assurance to be performed during ongoing production (Fig. 8). The accuracy of CT scans is dependent on the part size: for a part length of 250 mm, for example, the accuracy is 4/100 mm. The monosandwich process, with its proven history, will bring about many further interesting applications in the future because increasing cost pressures are forcing the search for simple, safe and inexpensive processes. There is great potential for application here slumbering away unused. Any plastic processor who raises the topic of the monosandwich process during design discussions with end customers and who scrutinizes his shop for potential applications is sure to strike gold. www.ferromatik.com

References 1 Färber, C.: Projektarbeit “Monosandwich”. Fachschule für Kunststofftechnik, Rehau 2007 The Author Dipl.-Ing. (FH) Helmut Kraft, born in 1954, is a sales representative for injection moulding machine manufacturer Ferromatik Milacron in south-eastern Bavaria, and is a founder of the Training Centre for Injection Moulding in Regensburg, Germany; www.spritzgießführerschein.de Published by courtesy of Kunststoffe

ELEKTRA K-TEC MAXIMA VITESSE F-SERIES

TRIBUTES FAREWELL FRANZ BENDIG

PEOPLE

FIRST SA EXHIBITOR AT K SHOW

FRANZ Bendig, one of the most effective machine suppliers in the SA plastics industry to date, passed away in September. He was 71. A larger than life character who became well-known in the industry, Franz was born in Germany, near Düsseldorf in the west of the country, in 1940, just as the country was in the grip of the war conflagration and the depravations that followed. His early years would hence have been challenging, but Franz got a good education and training and he must have felt he’d landed on another planet when he arrived in Johannesburg in the 1960s. It was sunny, people were friendly and there were opportunities galore. He first worked in the heavy-duty electrical sector, involved with the construction of large power stations. Not long after that he changed careers completely and joined JJ Allman Sales, an equipment supply business for the plastics industry. Franz learned the ropes quickly and by the time he left to start his own company, Adron, several of the principals went with him, and more followed. In the 1970s he represented several top European equipment suppliers such as Bandera, Coemter and Arvor. Being of mechanical mind, he set up Adron as a machine shop offering comprehensive technical support. Franz also realized the importance of having machines in stock, and based on solid financial management, was able to keep models of the most popular machines on the floor. Converters were, as a result, able to get machines virtually on request from Adron, rather than wait months as they sometimes had to with other suppliers (and there weren’t that many in the 1970s). Adron also built its own equipment, among its achievements being the development of the ‘Gapa’, the South African bag-making machine. One of Franz’s greatest accolades was that he was probably the first South African to exhibit at the ‘K’ show in Germany, and it was something of a triumphant return to the show’s base, his ‘hometown’ Düsseldorf, for the man. With the success achieved, Franz also developed an impressive lifestyle: he had a yacht on the Mediterranean and at one point even operated a helicopter. Rumours that he had a fleet of exclusive cars also did the rounds. These were things that most others could only dream of, but at the end of the day, Franz wasn’t a dreamer. He was not a big talker, and did not say things he didn’t mean. So it’s undoubted that he set a big example, which is never more so evident than in the fact that several of the people who worked for him went on to run very successful businesses after leaving Adron, notably Tony Varrie at Plasquip and Paul Clark at Adex. 74

DECEMBER 2011 / JANUARY 2012

New training exec for PSA

PSA gets marketing exec

PLASTICS|SA has appointed Kirtida Bhana as the new Training Executive. Kirtida will be based fulltime at the Plastics|SA head ofﬁce in Midrand. Kirtida qualiﬁed with her B Tech Degree in Polymer Technology in 1995. She has been involved in the local plastics industry since 1989 when she started at Megapak as a lab technician and moved on to become the quality assurance manager. Kirtida worked in marketing and sales for a short while before joining the former Plastics Federation as a trainer from 1999 to 2002. She has since freelanced as a training and development consultant involved in various training initiatives within and outside the plastics industry.

PLASTICS|SA has appointed Monya Vermaak as Marketing and Communications Executive. Monya has more than 17 years’ experience in the communication, media and marketing ﬁeld. Before joining the plastics industry she was head of Internal Communications at Parliament and Public Communications Manager at the USA Embassy. “Some of the major challenges for me will be to roll-out the new Plastics|SA brand, representing an industry that is vibrant, poised for growth and ready for change. Another will be to make the whole of South Africa aware that plastic is too valuable to waste, and that it can be reused and recycled,” she said.

ON THE MOVE IT’S WELCOME back to Neville Breytenbach, who’s joined Aluminium & Chemical Resources in Johannesburg. ACR is the SA agent for Azelis of Europe, a top supplier of a whole range of chemicals. Neville was originally at BASF, but moved into the aluminum supply area with Alcan in 2006. Now, five years on, Neville is back in the industry, supplying additives and engineering materials. There has been a major change of the guard at FIMA in Krugersdorp, the BOPP film supplier. Pieter Swart, Patrick Munyambate and Dave Bragge have all left. Patrick is operating as a consultant at the moment, and Dave has moved to Universal Labels. In what’s virtually the end of an era, Robbie Butschi has relocated to Malaysia where he’s working for Limax, the bag-making machine manufacturer in Kuala Lumpur. Robbie was behind the development originally of the ‘Gappa’ bag-maker while at Adron, and since the closure of that business he’d been working at Technimac in Johannesburg. He was made an offer by Limax and decided to make the move. Building machines is easier in Malaysia than SA, said Robbie: engineering components cost significantly less, are of a suitable quality and the cost of living is a lot less than Jozi. The only thing is the temperature, said Robbie, it varies from very hot to very, very hot (said in less polite terms). Limax’s machines are sold locally by Maritime (www.limax.com.my). John Wilmers of Ultrapak in East London is taking a ‘gap’ year (yep, it’s not only school leavers who get such opportunities) and got the process off to a flying start with a 3-month safari around southern Africa, which he recently returned from. John sold his shares in Ultrapak to owners Astrapak group a number of years ago and completed a management period before the travel bug bit. National Rubber/Matmin’s Brian Beckwith has relocated to Langkawi (an island off the North West coast of Malaysia). After over 40 years in the SA rubber industry – during 17 of which he was treasurer for the Natal Branch of the IOM³ - Brian and his wife felt like doing something ‘new’. They had visited Malaysia on a few occasions and fallen in love with the country and its people. To add to that, the Ma-

laysian government started the ‘Malaysia My Second Home (MM2H)’ incentive scheme a few years ago, offering a renewable, 10-year, multiple-entry visa for qualified applicants who want to reside in a ‘second home’ in the country. In terms of the incentive scheme, participants are allowed to work for only 20 hours a week, so Brian has decided rather to retire completely and all he needs now is to find someone with whom to play tennis! Peter Raubenheimer has left Winplas in Johannesburg and is pursuing other interests. Herman Jacobs, ex-East Rand Plastics, is now running a mine in Zimbabwe. The position came up unexpectedly, and Herman is enjoying the change of scenery and business. Peter Waldburger has joined Enviroserv in Johannesburg. Horst Weinert has been appointed Didactic Manager for Festo South Africa. Weinert is a qualified Mechatronic and Mechanical Engineer, and has an MBA from Esslingen University of Applied Sciences in Germany. Since 1998 he has gained significant experience in sales of didactic learning systems and engineering and has been promoted from Training and Consulting Manager to his current position. With this appointment Festo hopes to allow for expansion of the Didactic business in South Africa as well as Southern and East Africa. Weinert also works closely with universities and colleges in developing Mechatronic Engineering, Automation and Robotics. Phil Mostert, formerly technical manager at one of SA’s top automotive component manufacturing groups in Durban, has gone on his own. After being integrally involved in mould development mainly from Taiwan, Portugal, Japan and other European countries, Phil’s tooling involvement spans 40 years. He has been kicking his heels in Hillcrest since the end of 2009 and is available for consulting and contract work, both tool related as well as actual moulding of components for the automotive and related industries; phone 083 678 2581. Dale Walker, ex-Industrial Urethanes, has joined BASF Polyurethanes SA (ex-CHC Elastogran).

COLOURS OUT OF THIS WORLD

For all your colouring requirements of masterbatch and pigments. Discover new horizons with Mercury Plastics. With the latest computerised colour matching facilities and 21 years expertise. Our highly skilled staff is at your service.

Impossible just won’t do! 21 YEARS DEKRA EN ISO 9001:2000

Established 1990

MERCURY PLASTICS (PTY) LTD Johannesburg: Tel: (011) 824 0350/1/2 • Fax: (011) 824 0353 • email: aussie@mercuryplastics.co.za • 153 Haring Road, Wadeville, Ext 2 Durban: Conrad Pillay 082 358 4727 • Cape Town 021 552 4433 •

INDUSTRY NEWS

First National Battery

celebrates 80 years More than 20 million plastic battery components produced each year FIRST National Battery (a division of Metindustrial (Pty) Ltd), South Africa’s leading manufacturer and distributor of lead acid batteries for use in automotive and industrial applications, celebrated its 80th anniversary this year. On 22 September 1931, the first dozen batteries produced in South Africa were delivered to motor traders in East London, Stutterheim and King William’s Town. Today more than 2.2 million lead-acid batteries are manufactured annually, from automotive to agriculture, mining, standby power for mission critical operations and more. The company also supplies calcium maintenance free lead acid batteries to original equipment manufacturers and has successfully developed and marketed hybrid technology automotive batteries using PbCa negatives and PbSb positives. A world-first is their patented flat-top central vented battery which meets the demands of the 76

DECEMBER 2011 / JANUARY 2012

high volume utility size vehicle segment. A comprehensive range of DIN truck batteries was launched earlier this year. More than 2.2 million batteries a year are processed through two East London factories. One factory produces automotive batteries, while the other is unique in that it was the ﬁrst facility in Africa dedicated solely to the production of industrial type batteries. The automotive battery plant is capable of producing some 10 000 batteries a day and comprises 11 700m2 factory area. The 22 800m2 industrial battery plant now produces materials handling, standby, mining and minelighting batteries as well as the advanced AGM (Absorbent Glass Matt) technology automotive battery range. In 1999 First National Battery acquired the Darmag plastic plant in Fort Jackson, about 20km from East London. This plant produces more than 20 million battery

Renewable energy installation – FNB not only supplies the batteries for renewable energy but complete load management systems. These store energy from renewable sources and distribute it as needed. This is a solar example. Solar installation at Paarl – These batteries are storing energy sourced from the sun for later use in this industrial environment

components each year in a 7 800m2 factory which houses plastic injection moulding equipment from 50 ton to 850 ton capacity. www.battery.co.za

NEW CLARIANT INNOVATION PORTAL

USEFUL INFO ON THE INTERNET VIDEOS EXPLAIN HOW EXTRUSION CONTROL SAVES MATERIAL TWO new videos posted on the Maguire Products home page show how the LineMasterâ&#x201E;˘ extrusion control system operates and how it saves costs, increases productivity and enhances product quality. Included is a two-minute overview and a comprehensive 18-minute video. Presenter Chris Crittenden, sales manager for Maguire Europe, shows that the LineMaster system can exert precise control over throughput (kilograms per hour) or product yield (grams per metre). Among the beneďŹ ts he cites for processors are: â&#x20AC;˘ Accuracy within 0.5% of target; â&#x20AC;˘ Up to 4% savings in raw material; â&#x20AC;˘ Faster start-ups and quicker job changes, with less scrap; â&#x20AC;˘ Complete documentation. Maguire is represented by Hestico. www.maguire.com

Chris Crittenden of Maguire with a Loss in Weight (LIW) hopper

THE EASY WAY TO FIND INSULATION SYSTEMS & MATERIALS DUPONT Performance Polymers has introduced a fast, easy way to discover Electrical Insulation Systems and Materials (EIS/EIM) for application with its new website and selector tool. The website is comprised of two parts: 1. Information pages: Including an introduction to EIS and DuPont EIS offerings, application & technical information, and other product information. 2. Selector tool: A newly designed selector tool enables users to ďŹ nd, compare, modify and request authorization of selected pre-approved UL 1446 (IEC-60085) systems, featuring DuPont materials, all within a few clicks. The website, with the ability to select systems, is a great resource to maximize applications.

UNLOCK the secrets to successful innovation at Clariantâ&#x20AC;&#x2122;s new innovation web-pages. Visitors to www.innovation.clariant.com are invited on a journey through the chemistry behind the challenges critical to societyâ&#x20AC;&#x2122;s safety and advancement. They can also ďŹ nd out how they can work with Clariant to contribute to a sustainable and comfortable future. For news on issues that impact daily life, visitors can sign-up to the new quarterly webmagazine â&#x20AC;&#x153;Innovation Spotlight â&#x20AC;&#x201C; the chemistry behind your comfortâ&#x20AC;?. Animations show how the products we use in our daily life are made eco-friendlier, more efďŹ cient, and saver through ClariantÂ´s chemistry. With its easy-to-follow explanations the new web-page also provides an educational and inspirational insight into chemistryâ&#x20AC;&#x2122;s role in cutting-edge technology such as renewable energy and raw materials, water management, and advanced materials. In addition, details of the innovation process at Clariant highlight the specialty chemical expertâ&#x20AC;&#x2122;s focus on ensuring its organization is bestequipped to support its customers.

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DECEMBER 2011 / JANUARY 2012

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INDUSTRY NEWS

New horizons, challenges & Additive manufacturing is chance to steer creative capacity to accelerated innovation and product delivery

Prof Deon de Beer, of the Vaal University of Technology (VUT) and organiser of this year’s RAPDSA conference, welcomed opening speaker Prof Alwyn Louw, Deputy ViceChancellor: Academic & Research at VUT

DECEMBER 2011 / JANUARY 2012

INNOVATION and cutting-edge technology were the order of the day at the annual RAPDASA Conference in Vanderbijlpark in November. Hosted by the Rapid Product Development Association of South Africa and the Vaal University of Technology, delegates, speakers and visitors to the conference were treated to a diverse range of presentations from both local and international speakers, as well as workshops and exhibitions. Sessions over the three days included a range of presentations on material and applications, medical product development, design and direct manufacturing, tooling, tissue engineering and much more. In his welcome speech, Professor Alwyn Louw, Deputy Vice-Chancellor: Academic & Research at the Vaal University of Technology (VUT), said: “It is evident that the process of rapid prototyping, additive manufacturing and related creative design, prototyping and manufacturing options progressively provides the opportunity to facilitate a broad opportunity to the mainstreaming of creative capacity towards accelerated innovation and product delivery.”

“The beneﬁts in terms of time, cost, competitive positioning linked to growing broad-based participation and advancement is evident,” he added. Prof Louw said that the large number of international and local speakers and participants, linked to the excellent technology platform and services exhibition added signiﬁcant value in steering additive manufacturing development further, not only in SA, but internationally. “VUT is committed to continue its partnership with our colleagues in the academic fraternity as well as with industry. Our research, innovation and technology transfer capacity continue to grow rapidly. The network of collaborations and the existing new developments in sectors like the shoe, foundry and related steel industries, presents exciting new developments,” he added www.vut.ac.za www.rapdasa.org

opportunities 1

REGLOPLAS High-performance temperature control units ... for large injection moulds, extruders, rollers, autoclaves and other processing equipment

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capacity: 60 litres/min: 3,8 bar

ACHIEVES 24% reduction in rejects and 20% INCREASE IN PRODUCTIVITY

Type 150 Smart

Controller RT60-PID yields: Simultaneous readout of temperature set-point and actual value; Clear arrangement of operating and indicating elements; Solid-state relay (SSR) instead of heating contactor.

1. The executive management expressed their appreciation to the ladies who put in many hours of work to make the conference such a success, Rynette Coetzer, Jenny van Rensburg and Zelda Kotze 2. Piet Bezuidenhout of Sasol with doyen of the South African rapid prototyping arena, Bob Bond 3. Dr Terry Wohlers, president of Wohlers Associates in the USA, gave the keynote address on ‘New trends in additive manufacturing’

4. Dr Eric Klemp, Prof Dimitri Dimitrov and Marius Vermeulen of Stellenbosch University New horizons, challenges & opportunities 5. Louis du Toit and Grant Ravenscroft of DemaPlasTech who exhibited at the RAPDASA conference 6. RAPDASA committee, from left, Piet Bezuidenhout, Dr Neal de Beer, Marius Vermeulen (Chairman), Gerrie Booysen, Prof Deon de Beer, Hardus Greyling, Dr Willie du Preez and Eugene Erfort (Treasurer)

DECEMBER 2011 / JANUARY 2012 81

Outlet temperature max: 150°C Heating capacity at 400V: 6kW Cooling capacity: 28kW Pump capacity: 60 litres/min: 3,8 bar All components exposed to water are made of nonrusting materials, hence long service life

JENOWILL SERVICES Contact - Willy Tschopp 28C Lilly Park, Railway Rd Montague Gardens, Cape Town

Tel: 27 21 551 7241 Fax: 27 21 551 7243 E-mail: jenowill@iafrica.com

www.regloplas.com

MATERIALS

Complex delicacy ACCORDING to Oriflame, the natural Swedish cosmetics major, its fragrance Muse (available as an Eau de Toilette in bottles of 50 ml) conjures images of a meadow of deliciously fragrant flowers. Violet flower, one of the key notes of the fragrance, is also reflected by the exquisite bottle, shaped like a stem, and a flower-shaped cap, moulded from DuPont™ Surlyn®, with petals in full bloom. By achieving such a complex shape as a single, injection-moulded part, the moulder Aarts Plastics (Waalwijk, the Netherlands) delivers the full aesthetic potential of the DuPont material. The intricate design of the petals, consisting of numerous thin- and thick-walled sections, are faithfully reproduced in Surlyn, while the material’s compatibility with colouring using masterbatch ensures close compliance with other elements of the perfume’s packaging. • PLASTAMID SUPPLIES THESE MATERIALS FOR DU PONT IN SA

www.dupont.com

Macrolex is first choice FDA-compliant colorants from Lanxess for Eastman Tritan polymer MACROLEX colorants from Lanxess have once again proven themselves in the plastics sector: The renowned U.S. legal firm Keller & Heckman LLP based in Washington, D.C., has certified that Eastman Tritan coloured with Macrolex colorants meets the requirements of the United States Food and

Drug Administration (FDA). Their opinion is based on results from trials and extensive toxicological testing. Specialty chemicals company Lanxess worked with Eastman Chemical Company, manufacturer of Tritan, in selecting 10 Macrolex colorant grades to demonstrate their speciﬁc suitability for

www.lanxess.com colouring the copolymer. Eastman Chemical Company, a U.S. based company with operations around the world, is the leading manufacturer of polyester plastic for packaging. In 2007, Eastman launched a polymer called Eastman Tritan that balances the properties of clarity, toughness, dishwasher durability and high heat and chemical resistance. An additional bonus is that it is free of bisphenol A (BPA). The 10 Macrolex colorants meet FDA requirements up to a total content of 0.2%. This is a considerable amount in view of the high tinting strength. These bottles are made in the USA from Eastman Tritan copolyester manufactured without Bisphenol A (BPA)

Innovative single-use syringes AMERICAN company Plas-Tech Engineering, Inc., a custom moulder specializing in innovative medical components, has selected Medalist® elastomers as one of several highperformance alternatives to conventional materials for a new range of single-use syringes. Plas-Tech uses Teknor Apex’s Medalist medical elastomers instead of thermoset rubber for the tiny plunger tips or seals that prevent drugs in the tube or barrel of the syringe from flowing backward as the plunger is depressed. For the plungers and barrels in one series of syringes, the company uses polycarbonate as a durable alternative to polyolefins; for two other series, Plast-Tech moulds these components out of cyclic olefin polymer and copolymer, respectively, as shatter-resistant alternatives to glass. While 82

silicone coatings are widely used to ensure smooth movement of the plunger within the barrel, Plas-Tech uses a non-silicone coating to prevent possible interaction with the drug contents. Of close to three-dozen standard grades in the Medalist range, Plas-Tech chose two compounds for the plunger tips: translucent Medalist MD-145 in the polycarbonate syringes and clear Medalist MD-555 in the cyclic oleﬁn syringes. The MD-555 grade was chosen for its compatibility with cyclic oleﬁns, which can undergo stress cracking upon exposure to many TPEs. • ADVANCED POLYMERS IS THE SA AGENT FOR TEKNOR APEX

Plas-Tech uses Teknor Apex’s Medalist medical elastomers instead of thermoset rubber for the tiny plunger tips or seals that prevent drugs in the tube or barrel of the syringe from ﬂowing backward as the plunger is depressed

www.medalistmd.com www.teknorapex.com www.plastechengineering.com

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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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

Winter in the outskirts of Teheran

IR AN A ENCE PRESindu GIGANTIC poly stry mer in Middle East

FEATURE

Niall Marshall, our man in Bahrain, reports that around 5.5 million tons of polymers are manufactured in Iran per year PERSIA has always been a gigantic presence in the Middle East: 2500 years ago the Persian Empire stretched across three continents from India to Libya and as far north as Greece with many of the cultural behaviours and technological advances of the Persians being adopted by the Greeks and so influencing western civilization. Modern day Persia, the Islamic Republic of Iran, continues to wield an influence beyond its borders. A heady mix of confident self-assertion, historical rivalries with its Arab neighbours and a resentment about what it sees as a century of self-interested interference by western countries in its domestic affairs, leads to the present-day stalemate involving IAEA inspectors, wide ranging sanctions and regular newspaper headlines. But hidden behind all the ‘news’ is something very interesting: a gigantic plastics industry. Iran is blessed with the world’s second largest oil reserves (after Saudi Arabia) and the world’s second largest gas reserves (after Russia). Add to this a relatively well educated population of 73 million people and a large manufacturing sector and you have what was, until recently, the largest economy in the Middle East, comparable in size to South Africa. As might be expected in a country with enormous oil and gas reserves the petrochemical industry is a focus of growth. Responsible for all petrochemical production, including oil refineries, chemical plants and polymer manufacturing, is the National Petrochemical Company (NPC) with more than 50 subsidiaries including joint ventures. A massive plastics industry In the 1990s two special petrochemical 84 DECEMBER 2011 / JANUARY 2012

Teheran

BY NIALL MARSHALL

development zones were established, one at Bandar Imam on the Persian Gulf close to the Iraqi border and the second at Assaluyeh, across the Gulf from Qatar. Combining the capacity of older (and smaller) polymer plants elsewhere in Iran and the new world-scale plants recently commissioned in these petrochemical zones, there are around 5.5 million tons of polymers manufactured in Iran per year including polypropylene, polyethylene polycarbonate, polystyrene, PVC and synthetic rubber. To put this into context, Saudi Arabia manufactured about 12.6 million tons of polymers in 2010 following massive investments over the last five years; in 2006 the Saudi polymer capacity was less than 5 million tons! In Iran there are a number of projects delayed due to the non-availability of western engineering firms as well as plans for a ‘West Pipeline’ running along the western border with Iraq where new polymer plants will be built, adding another 2-3 million tons of capacity. Shortages of skilled labour, feedstock For all its cheap feedstock and world class plants the Iranian petrochemical industry is hindered by a shortage of experienced and skilled labour (any sector that expands as fast as the Middle East polymers industry will struggle to find sufficient experienced labour, and while Saudi Arabia can recruit ex-pat workers, Iran doesn’t really have that option) and increasingly tight sanctions. There are also feedstock shortages, ironically caused by state subsidies. Government subsidies of petrol in Iran (only R0.85/ litre) have resulted in limited investment in oil refineries and so most petrol sold in Iran has to be imported. This has not only led

to shortages of petrol (motorists are limited 500 litres per month with only the first 60 litres subsidized, the balance is about R4.80/ litre) but also to limited chemical feedstock for polymer plants. Refinery and cracker expansions are delayed due to difficulties in accessing international funding due to sanctions. The Iranian plastic industry is not only about producing polymers, there is a large, but fragmented, converting industry supporting domestic automotive and appliances industries, as well as packaging, construction and agriculture sectors. Anyone who has ever heard of ‘Persian carpets’ will be aware of the county’s long history in floor coverings. More than 600 000 tons of fibres are produced each year by over 50 converters. However, a focus on domestic markets for most converters protected from serious competition from imported goods due to sanctions has resulted in a generally inefficient downstream industry. To look at a snapshot of the Iranian polymer industry today, with its large exportfocussed polymer plants facing the challenges of international sanctions and its large domestic-focussed converting industry made up of many small converters competing with inefficient local competitors, is to miss the big picture: this is a country that can, under the right circumstances, be an influential player in the global polymer market, competing in terms of a low-cost feedstock and modern polymer production technology with any other Middle East producer. Iran is a gigantic presence in the Middle East polymer industry. NIALL CAN BE REACHED AT: NIALL.MARSHALL@EVERSPRINGME.COM

New initiatives for Plast in Italy in May PLAST 2012, taking place in Milan from 8-12 May, will be the largest European trade show comprehensively covering the machinery, equipment, moulds, raw materials, regenerated materials, composites, and semi-finished and finished products for the plastics and rubber industry. The show is expected to match the records set by the preceding edition of Plast, in March 2009: namely 1478 exhibitors from 45 countries, occupying a total floor area of 59,000m² and drawing 55,175 visitors of which over 31% (17,589) were from foreign countries. In all, individuals from a whopping 114 countries were present at the show. Plast 2012 will also see the return of the ‘Rubber 2012’ satellite event. New to Plast will be an international ideas competition called the Plastic Technology Award. The competition topics relate to innovations and original applicative solutions connected with the main plastics processing technologies. There is also a rich programme of sideline events, technical-scientific conferences and company presentations. The conferences already scheduled include one on biodegradable materials, and one on the applications of plastics in agriculture. www.plastonline.org Plast 2012 hopes to match records set by the 2009 edition which boasted 1478 exhibitors from 45 countries, over a total floor area of 59,000m² and drawing 55 175 visitors

Efﬁcient production: A six-axis robotic system combines injection moulding and foaming in the Mold’n Seal process

Arburg success at Fakuma 2011 THIS year’s appearance at the Fakuma international plastics trade fair in Friedrichshafen was a resounding success for Arburg. In addition to celebrating the ‘50 years of Allrounder’ anniversary and presenting the new Edrive injection moulding machine series, the Lossburg-based machine manufacturer also focused on the multi-faceted subject of energy and production efﬁciency. Arburg’s two-storey exhibition stand with about 1,300 m² ﬂoor space, showcased 12 exhibits, with a further 10 machines on external stands. An impressive demonstration was provided of the performance and broad range of applications offered by Arburg machines and production cells, with the production of a wide variety of plastic products. On view were applications from the areas of multi-component technology, LSR processing, medical technology, optics, powder injection moulding and the production of sophisticated hybrid components, automotive products and packaging. On the machine side, the focus was on the new Edrive series, which supplements the range of electric machines and is designed for standard applications. An Allrounder 570 E was used to present the Mold’n Seal process in which a six-axis robotic system is used to combine injection moulding and foaming. www.arburg.com

2012 EVENTS

DIARY

RUSSIAN SHOW INTERPLASTICA in Moscow from 24-27 January is regarded as the leading platform for plastic and rubber technology in Russia. According to organiser Messe Düsseldorf, of Germany, consumption of plastic in Russia still holds considerable potential for growth. Above all in the areas of packaging and medical technology, production capacities are being expanded and modernised across the country. The backlog demand in the construction and infrastructure sector is immense, and it is just as great in the consumer goods sector. The 2012 show will be the 15th edition of Interplastica. www.interplastica.de

STAR ROTOMOULDING CONFERENCE THE 9th annual Rotomoulding Conference will be held at the Crowne Plaza, Okhla, New Delhi, India, from 29-31 January. The StAR Rotomoulding Conference has been acclaimed internationally time and again for its breadth of rotomoulding content presented by an array of globally renowned speakers. A notable feature which is becoming more and more established over the years has been the variety of business alliances which materialise between 86

DECEMBER 2011 / JANUARY 2012

lndian companies and leading international companies who attend the StAR conference. www.starasia.org

POLYESTER & PET CHAIN 2012 THE 16th Annual Polyester & PET Chain World Congress will take place from 14-16 February in Zurich, Switzerland. The Polyester fibre and packaging industries have been recovering from the downturn in demand following the worldwide economic crisis and volumes are increasing. However margins are now being squeezed by increasing feedstock costs. At this unique event analysts from CMAI and SRIC will delve into whether the recovery can be maintained or whether the next investment wave will again lead to low capacity utilization and poor profitability. The 16th Annual Polyester & PET Chain World Congress brings together industry leaders from around the world to focus on the new technology, product and application directions needed to sustain growth and maintain profitability as markets recover worldwide. www.mbspolymer.com

PLASTEX 2012 PLASTEX 2012 from 26-29 February in Egypt is the leading international trade fair dedicated to the plastic

machinery, components, raw materials and chemicals in the Middle East & North African regions. The fair presents products and services, technologies and innovations, trends and tendencies for trade markets. It is an international meeting-place for worldwide suppliers and regional manufacturers. Since its launch in 1993, Plastex has held 12 successful versions and the 13th is expected to attract even more exhibitors, visitors, and international attendance in addition to increasing space. www.plastex-online.com

TYREXPO AFRICA 2012 MAJOR names from Southern Africa’s tyre and equipment sector have announced plans for a strong presence at Tyrexpo Africa 2012 at the Sandton Convention Centre, Johannesburg, from 6- 8 March. Since its launch in 2004, Tyrexpo Africa has established itself as an inﬂuential niche event that brings together leading domestic and international suppliers specialising in tyre and equipment manufacturing, distribution, retailing, servicing and repair. The 2012 exhibition promises to be the best-attended yet, with many companies from across the global tyre industry expressing interest in doing business in southern Africa. www.eci-international.com

2012 INTERPLASTICA: 24-27 January Moscow, Russia: www.interplastica.de STAR ROTOMOULDING CONFERENCE: 29-31 January New Delhi, India: www.starasia.org AMIâ&#x20AC;&#x2122;S THERMOPLASTIC CONCENTRATES: 31 Jan-2 Feb Coral Springs, Florida, USA: www.amiplastics-na.com PLASTINDIA 2012: 1-6 Feb New Delhi, India: www.plastindia.org AMIâ&#x20AC;&#x2122;S POLYETHYLENE FILMS 2012: 9-10 Feb Daytona Beach, Florida, USA: www.amiplastics-na.com POLYESTER & PET CHAIN 2012: 14-16 Feb Swissotel, Zurich, Switzerland: www.amiconferences.com GRASS YARN & TUFTERS FORUM 2012: 20-22 Feb Swissotel, Zurich, Switzerland: www.amiconferences.com

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PLASTEX 2012: 26-29 Feb Cairo-Egypt: www.plastex-online.com PIPELINE COATING 2012: 27-29 Feb Vienna, Austria: www.amiplastics.com/Events TYREXPO AFRICA 2012: 6-8 March Sandton Convention Centre, Jhb: www.eci-international.com ENERGY STORAGE SUMMIT: 13-14 March DĂźsseldorf, Germany: www.energy-storage-online.de

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GREEN POLYMER CHEMISTRY: 20-22 March Maritim Hotel, Cologne, Germany: www.amiplastics.com

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PVC FORMULATION 2012: 20-22 March Dusseldorf, Germany: www.amiplastics.com/Events WORLD PULTRUSION CONFERENCE: 22-23 March Istanbul, Turkey: www.pultruders.com TUBE 2012: 26-30 Mar Dusseldorf, Germany: www.tube-tradefair.com WIRE 2012: 26-30 Mar Dusseldorf, Germany: www.wire-tradefair.com NPE 2012: 1-5 Apr: Orlando, Florida, USA: www.npe.org

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INDOPLAS 2012: 11-14 April Jakarta, Indonesia: www.indoplas.com

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IISRP AGM: 16-19 April: Venice, Italy: www.iisrp.com

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4TH PAINTEXPO: 17-20 Apr: Germany: www.paintexpo.com

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CHINAPLAS 2012: 18-21 Apr Shanghai, China: www.chinaplasonline.com DIEMOULD INDIA: 19-22 Apr Mumbai, India: www.demat.com POLYMERS IN PHOTOVOLTAICS 2012: 24-26 Apr Maritim Hotel, Cologne, Germany: www.amiplastics.com SPE THERMOFORMING CONFERENCE: 25-27 Apr Venice, Italy: www.e-t-d.org DRUPA 2012: 3-16 May Dusseldorf, Germany: www.drupa.com BIOPLASTICS COMPOUNDING&PROCESSING: 8-9 May Miami, Florida, USA: www.amiplastics-na.com/Events WAITEX: 8-10 May Lagos, Nigeria: www.exhibitionsafrica.com

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AFRICA INFRASTRUCTURE: 8-11 May ExpoCentre, Johannesburg: www.africainfrastructure.co.za PLAST 2012: 8-12 May Fiera Milano, Milan, Italy: www.plastonline.org PLASTIVISION ARABIA 2012: 14-17 May Expo Centre Sharjah: www.plastivision.ae INTERPLAS THAILAND 2012: 21-24 Jun BITEC, Bangkok: www.interplasthailand.com EUROMOLD BRASIL: 20-24 Aug Joinville, Brazil: www.euromold.com

DECEMBER 2011 / JANUARY 2012 87

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PlastIndia draws interest from around the world 130,000 visitors, 1,500 exhibitors expected RIGHT at the beginning of 2012, Plastindia from 1-6 February in New Delhi, is the sector’s most important trade fair on the Indian subcontinent. Due especially to the startling growth in the industry in India in recent years, there has been vigorous demand for exhibition space from machinery and raw material manufacturers as well as plastic and rubber processors from around the world, wishing to present their innovations in this very promising market. Consumption of plastic in India has increased dramatically, and is expected to reach 15 million tonnes in 2015. Likewise, the number of machines in operation is also large – an estimated 69,000 machines were in operation in India in 2009 – and the ﬁgure is most likely growing rapidly too. PlastIndia takes place at the Pragati Maidan fairgrounds in New Delhi. In 2009, the fair attracted 130,000 professional visitors who saw the presentations of around 1,500 exhibitors. The organising partners, Plastindia Foundation and Messe Düsseldorf, expect PlastIndia to be completely sold-out. The European countries with especially strong representation include Belgium, Germany, France, the UK, Italy, the Netherlands, Austria, and Switzerland. In addition, a joint presentation from Turkey will be premiered. www.plastindia.org

DIARY

Roto Solutions only SA exhibitor at Chicago roto show ROTO Solutions was the only South African exhibitor at the recent Rotoplas ’11 show (2-3 November) in Chicago, USA, and Gary Lategan was able to report some exceptional activity on his stand. He sold two of Roto Solutions’ ‘TempLogger’ temperature monitoring/control systems as well as a number of the ARMO-approved Dry Flow & Bulk Density Testers. And that’s besides the good number of leads yielded from roto moulders in North America as well as international guests at the show. Gary also operates as a rotational moulding consultant, and is ﬁnding some areas of common interest with US roto companies. During his visit to the USA, Gary also attended a ‘Q Desk conference’ for two days, which he described as a unique setup, plus he was involved in a ‘What’s Your Problem’ workshop. Rotoplas, one of the premier world events for the rotational moulding industry for the past 30-plus years, is presented by the USA-based Association of Rotational Molders (ARM). www.rotoplas.org

Chicago show – The Roto Solutions/ TempLogger stand at the Rotoplas ’11 show in the USA was rated as the busiest by exhibitors around the booth, but Gary was uncertain if it was his products and style or that of his interpreter, Missy! She is able to converse in both French and Spanish

www.rotosolutions.co.za

Qdesk convention – Prior to the Rotoplas show, Gary attended a ‘Qdesk convention’ coordinated by QProducts of Florida, USA. A roto moulded school desk marketed as an “eco-friendly desk alternative for the home and the classroom”, the Qdesk is made in various colours that give school classrooms “the fun look that children love”. It won a design award at the 2009 NPE show in the USA. Gary was a guest at the convention, where Qdesk sales licensees gathered. The interesting aspect was how the manufacturer had managed to retain control sales of its products. QProducts, LLC is a multi-national organisation dedicated to the design, manufacture and commercialization of unique roto moulded products. The Qdesk is available in various sizes.

2012 EVENTS NPE WILL BE BIG RUNNING from 1-5 April in the Orange County Convention Centre, Orlando, Florida, USA, NPE 2012 will be an exciting show, bigger than the last event in 2009, with larger booths, more equipment operating on the exhibit ﬂoor and many ﬁrst-time participants drawn to the new venue. NPE is a triennial international plastics exposition produced by SPI, the Society of the Plastics Industry of the USA. The show will include 2 000 companies exhibiting on 93 000m² and is expected to be visited by industry professionals from 120 countries. Co-located events will include SPE Antex® 2012, the world’s largest plastics technical conference; SPI’s 88

DECEMBER 2011 / JANUARY 2012

‘Business of Plastics’ conference; and the second annual International Plastics Design Competition. www.npe.org

ZONE IN AT CHINAPLAS THE other event in the ﬁrst of 2012 of special interest is Chinaplas, from 18-21 April at the Shanghai New International Expo Centre, PR China. Following the impressive results gained from the Bioplastics & Degradable Plastics Zone as well as the Rubber Machinery & Equipment Zone at the 2011 show, both events are to be repeated. Another feature expected to be prevalent is the increased number of Japanese exhibitors. Visitors from

Japan have historically constituted one of the largest groups of foreign participants at the show, but the trend has changed somewhat in that many Japanese companies have been setting up production plants in China, and it appears that many of these China-based entities will now be exhibiting. Most of these plants appear to be situated in Eastern China. The 2012 event will be the 26th edition of Chinaplas. www.ChinaplasOnline.com

DRUPA IN MAY DRUPA, the world show for the print media which takes place every four years, is to run from 3-16 May. www.drupa.com

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

AROUND THE WORLD NEUTREX EXPANDS ‘PURGEX’ CAPACITY NEUTREX of Texas, USA, has increased the size of its production facilities by 50% for the company’s line of Purgex Commercial Purging Compounds (CPC). The expanded facilities will be fully onstream by the end of 2011. The expansion will include additional manufacturing and warehousing capability to supply Purgex to its domestic market and to distributors in Europe, Asia, Africa and South America. The expansion will also allow the company more ﬂexibility in the development of new products planned for introduction in 2011. Introduced in 1992, Purgex is a CPC used to clean injection moulding and extrusion equipment during colour and material changeovers, and as part of routine or preventive maintenance. According to the company, Purgex cuts downtime, decreases scrap rates, and reduces the amount of otherwise usable resin wasted when purging. The overall effect is to lower purging costs and improve productivity for thermoplastic resin processors. s 0URGEX IS DISTRIBUTED IN 3OUTH !FRICA by Chemimpo (Pty) Ltd. www.chemimpo.co.za, www.PurgexOnline.com

EVONIK UPS GLOBAL PMMA PRODUCTION EVONIK Industries, one of the leading suppliers of methacrylate chemistry, is increasing the production capabilities of its methyl methacrylate plants throughout the world, to meet the rising demand. Evonik will increase their production capabilities of methyl methacrylate through debottlenecking and plant expansion projects in their existing plants in Europe (Worms and Wesseling in Germany), Asia (Shanghai in China), and the United States (Fortier) in 2011 and 2012. On completion of the projects Evonik industries will be able to produce approximately 50 000 additional tons of methyl methacrylate. Methyl methacrylate is primarily used for PMMA resins and surface coatings. www.evonik.com

UK GOVT SLAMMED OVER BAG CHARGE THREAT THE Carrier Bag Consortium (CBC) has condemned a statement issued in September by UK Prime Minister David Cameron that threatens retailers with legislation forcing them to charge for plastic bags. A CBC spokesman said: “In the face of massive economic pressures it is a great shame that the Prime Minister is suggesting taxing the ordinary shopper, particularly when this ﬂies in the face of the evidence from his own Environment Agency, which proves that the lightweight plastic bag is the best environmental choice if re-used – as it is by 76% of households – or recycled.” Cameron should not lose sight of the fact that taking just one long-haul ﬂight is the equivalent of 500 years of carrier bag consumption in a typical household, pointed out the CBC.

Bioplastics Awards DANONE Germany and Switzerland were named the overall winners in the prestigious 6th Bioplastics Award, organised by bioplastics MAGAZINE and judged by the academic world, the press and industry associations from America, Europe and Asia. The awards recognise innovation, success and achievement by manufacturers, processors and users of bioplastic materials. To be eligible for consideration in the awards the company, product, or service must have been developed or on the market in 2010 or 2011. The winning entry - Danone Germany and Switzerland: launch of Activia and Actimel dairy products in bioplastics packaging – showed how with their introduction of Activia and Actimel in packaging made of bioplastics (PLA und Green HDPE) Danone has signiﬁcantly contributed to establishing bioplastics for mass-market product applications. One of the various measures Danone uses is of biobased and partly biobased packaging - be it 100% biobased polyethylene, partly biobased PET, or 100% biobased PLA.

The winning entry! Danone has contributed to establishing bioplastics for mass-market product applications

BioSac - the ﬁrst biodegradable and compostable packaging for the cement industry

Four other companies/products were shortlisted: Limagrain Céréales Ingrédients (LCI): BioSac BioSac is the first biodegradable and compostable packaging for the cement industry and the latest application of LCI’s biolice. It has been developed collaboratively by LCI with the Barbier, Mondi and Ciments Calcia groups. The innovative nature of BioSac comes from the composition of its ‘free film’, which uses LCI’s biolice. Biolice is made using a unique bioplastics process with whole cereal grains from specific Limagrain maize varieties. The product’s innovation lies in the combination of cereal fractions with a biodegradable polymer. M-Base and University of Applied Sciences and Arts, Hanover, Germany: Biopolymer Database M-Base Engineering + Software GmbH, in cooperation with the Biopolymer Institute of FH Hanover, Germany, developed a

‘Electromobility’ solutions THE trend towards electromobility is unlocking a whole new range of applications for plastics and Bayer MaterialScience is developing innovative and sustainable solutions for future mobility concepts. This also applies to the build-up of the infrastructure, in particular the expansion of the network of electric charging stations. One of the latest examples of this is the ‘EV-Box’ charging station manufactured by Dutch company EV-Box B.V. Its housing is made from the PC+ABS (polycarbonate/acrylonitrile-butadiene-

styrene) blend Bayblend® FR 3000 from Bayer MaterialScience. A number of EV-Box stations are already in operation in Belgium, the Netherlands and now also in Düsseldorf, Germany. For the ﬁrst time, German drivers are able to ﬁll up their electric vehicles at these stations. The modular EV-Box features a stylish design and coloured lighting. It is intended for both private and public use and can be installed on streets, squares and parking lots or can be wall-mounted in the home.

WORLD NEWS

new biopolymer database with comprehensive technical information relating to the processing and utilization behaviour of biopolymers. The biopolymer database includes more than 100 biopolymer manufactures and more than 600 material types with uniformly tested mechanical and thermal properties. It includes an application database with many different representative examples and information about biopolymer products which can be accessed at www.materialdatacenter.com

Beaulieu Technical Textiles: Ökolys – The ﬁrst woven biodegradable and compostable agro textile Ökolys™ is a new sustainable range of woven groundcovers. Manufactured from a tailored and unique blend of two biopolymers, one biodegradable and one compostable, the Ökolys groundcover offers an environmentally-friendly innovative weed control solution. The groundcovers themselves eliminate the need for herbicides and manual maintenance and prevent erosion. Ökolys is essentially made of renewable primary materials and does not contain any harmful substances. After its period of use (2 - 3 years) Ökolys returns into the organic chain, closing the carbon cycle.

A new biopolymer database with comprehensive technical information relating to the processing and utilization behaviour of biopolymers

The Coca-Cola Company: The PlantBottle™ Packaging Coca-Cola has found a way to create one of the key ingredients in PET plastic, monoethylene glycol (MEG), from plants and about 30% of the PlantBottle packaging is made of this plant-based MEG ingredient. In addition to the Coca-Cola brand, PlantBottles with 14% plant based and 35% recycled content were introduced for the mineral water brand, Vio. One of the world’s largest ketchup makers ‘Heinz’, in cooperation with Coca-Cola, has also announced the use of about 120 million PlantBottles by the end of 2011.

PlantBottle™ packaging is the Coca-Cola Company’s breakthrough innovation Ökolys™ is a new sustainable range of woven groundcovers

Wind training! MOOG, a motion control solution provider and leading developer of pitch systems for wind turbines, has inaugurated its new Wind Training Centre in Unna, Germany. The 1,300 m² facility is designed to provide technical training programmes to Moog’s global wind energy customer base. A dedicated team of expert trainers will lead customer training programmes ranging from a basic introduction to more advanced and focused engineering courses on products and systems. Hands-on technical training in Moog Pitch Systems, Pitch Motors, Pitch Servo Drives, BackupSystems and Programmable Logic Controllers focuses on maintenance, performance analysis, repair and retroﬁts. To satisfy attendees with different backgrounds, basic, total immersion and expert levels will be available. www.moog.com/wind

www.bioplasticsmagazine.com

“Our material was chosen because it enables greater design freedom than metal. Because it is extremely tough even at icy temperatures, it can withstand extreme mechanical loads and vandalism. It also incorporates an effective, chlorine- and bromine-free ﬂame-retardance package and can be coloured freely, thus eliminating the need for costly paintwork,” says Dr Berit Krauter, a specialist in polycarbonate applications at Bayer MaterialScience. Another advantage of the heat-resistant material is that it allows the charging stations to be produced in large volumes much more cost-effectively than when using metal. Unlike sheet steel, it does not disrupt wireless and contactfree communication between drivers and charging stations via RFID and cell phone NFC systems (Radio Frequency Identiﬁcation and Near Field Communication, respectively).

A number of EV-Box stations electric vehicle charging stations are already in operation

www.bayermaterialscience.com 91

AROUND THE WORLD WORLDâ&#x20AC;&#x2122;S LARGEST POLYMER ANTIOXIDANT PLANT SONGWON Industrial Groupâ&#x20AC;&#x2122;s expansion of its antioxidant capacity from 55 000 to 70 000 tons has been completed ahead of time. This is the result of the consolidation of SongnoxÂŽ 1076 production into Songwonâ&#x20AC;&#x2122;s new fully backward integrated Maeam plant. In addition Songwon has announced the introduction of two enhanced physical forms of SongnoxÂŽ 1076: SongnoxÂŽ 1076 SB (semi beads) and SongnoxÂŽ 1076 CP (crystalline powder). The additional capacity is a key step in the organisationâ&#x20AC;&#x2122;s commitment to support the growing demand of the polymer industry. Maeam is now not only the biggest plant in the world dedicated to polymer antioxidants, but also one of the best manufacturing platforms delivering unequaled consistency and reliability of supply. s "ANBURY #HEMICALS IS THE 3! AGENT FOR 3ONGWON www.songwonind.com

Global environmental awards REFLECTING the theme of the American Society of Plastics Engineerâ&#x20AC;&#x2122;s Global Plastics Environmental Conference (GPECÂŽ 2011) in Atlanta during October â&#x20AC;&#x201C; Plastics Recycling and Sustainability on my Mind â&#x20AC;&#x201C; the 2011 environmental awards recognized companies and institutions that demonstrated environmental leadership and excellence through signiďŹ cant achievements in a variety of categories. www.4spe.org

www.sperecycling.org

Axion International (New Providence, NJ): â&#x20AC;&#x2DC;SigniďŹ cant Innovations in Environmental and Recycling Areas Using Conventional Plasticsâ&#x20AC;&#x2122; Award for developing highperformance composites from recovered polyoleďŹ ns and applying them as structural parts that can be used as components for bridges, railroad ties, and other structures that meet military speciďŹ cations.

LANXESS STEPS UP COMMITMENT TO CHINA ,!.8%33 IS STRENGTHENING ITS COMMITMENT TO SERVE the growing Chinese market with premium products by making a number of local investments totalling MORE THAN MILLION !MONG THESE THE COMPANY started up the third production line of its high-tech plastics plant in Wuxi, Jiangsu province. The 10 million-investment increases total capacities at the plant to 60 000 tons per year. The plant produces the innovative, lightweight plastics Durethan and Pocan that replace heavier metal parts in automobiles thus contributing to fuel efďŹ ciency and reduced emissions. China is the worldâ&#x20AC;&#x2122;s largest automotive market, and is expected to grow by 9% this year. www.lanxess.com

Futuris Automotive Interiors (Troy, MI): â&#x20AC;&#x2DC;Emerging Technologies in Materials, Processing, and Applicationsâ&#x20AC;&#x2122; Award for developing a mouldable, tufted PET carpet that is made with signiďŹ cant postconsumer PET content.

VERO SOFTWARE & PLANIT HOLDINGS MERGE 6%2/ 3OFTWARE A LEADING PROVIDER OF #!$ #!- #!% SOLUTIONS FOR THE TOOLING INDUSTRY HAS MERGED WITH 0LANIT (OLDINGS A LEADING DEVELOPER OF #!$ #!- SOFTWARE FOR THE PRODUCTION ENGINEERING sheet metal, metal fabrication and woodworking SECTOR 4HE MERGER CREATES THE WORLD S LEADING #!- SPECIALIST AND THIRD LARGEST #!$#!- VENDOR ONLY behind Dassault SystĂ¨mes and Siemens PLM.

RHEIN CHEMIE SETS COURSE FOR FURTHER GROWTH 2(%). #HEMIE IS INVESTING ROUGHLY MILLION IN a new production facility in Porto Feliz, Brazil, to MANUFACTURE 2HENOSHAPE HIGH PERFORMANCE CURING BLADDERS AND 2HENOGRAN PREDISPERSED POLYMER bound chemicals. Production is scheduled to be up and running by the fourth quarter of 2012. Production capacity in Porto Feliz will be 170 000 BLADDERS ANNUALLY 2HEIN #HEMIE ENTERED THE BLAD DER BUSINESS BY ACQUIRING THE !RGENTINIAN COMPANY $ARMEX 3 ! IN *ANUARY OF THIS YEAR )N "URZACO !RGENTINA PRODUCTION CAPACITY FOR BLADDERS CURRENTLY is being expanded by 40%.

Jenco gets stuck in UK manufacturer Jenco has won a ÂŁ300,000 order for the installation of six large feed systems for the adhesive manufacturer Beardow Adams in Milton Keynes, UK. The installation is in two phases: the ďŹ rst phase involves the vacuum conveying and blowing of EVA pellets, and the second phase involves vacuum conveying the calcium carbonate and other ďŹ ller powders used in the process. All of the design, manufacturing and engineering was carried out at the Jenco factory which is based in Essex. Both systems include weigh cells built in to the conveying process and the use of PLC control, enabling the company to monitor production ďŹ gures more precisely.

www.jenco.co.uk

Sika Sarnafil (Canton, MA): ‘Plastic Recycling Technologies and Applications’ Award for recycling old vinyl single-ply roofing back into useful roofing membrane.

At Fort Bragg, NC, an M1A1 tank is driven over a bridge made of a thermoplastic composite developed by Axion International. Made from some 85,000 pounds of recycled plastics, the bridge supports military equipment loads in excess of 70 tons. [PHOTO BY DAWN ELIZABETH PANDOLIANO

The organic waste bags made of BASF’s Ecovio FS do not affect the composition of compost: the density, content of water and salt, pH value, nutrients, percentage of organic matter and other components in the compost all remain unchanged

Compostable bags

Lehigh Technologies (Tucker, GA): Chairman’s Award for a process for large-volume production of micronized powders from discarded tyres that would otherwise be landﬁlled. The resulting powders can be used at high concentrations in plastics and new-tyre manufacture.

BD (Becton, Dickinson and Company) (Franklin Lakes, NJ): ‘Enabling Technologies in Processes and Procedures’ Award for a recycling programme that recovers plastics from medical devices and puts them to use in non-medical applications.

Integra Plastics buys Davis-Standard blown film systems DUE to demand for custom coextruded heavyduty film applications, Integra Plastics of Madison, South Dakota, recently purchased two high-output, three-layer blown film systems from Davis-Standard, LLC. The systems will occupy a new facility, slated for completion the beginning of 2012, and will support Integra’s film and sheet processes for industrial and agricultural membrane applications. One system will produce film up to 2 500mm wide and 8mm thick through the use of DavisStandard’s new Vertex co-extrusion die and

Triple Lip air ring technology. The Vertex die is engineered for tight gauge distribution and control while the Triple Lip increases cooling capacity over traditional dual lip designs. This system will also include SLC-1000 (Sliding Layon Carriage) surface winders for winding larger rolls. The SLC controls the winding force via pneumatics instead of hydraulics, and has better shaft performance for rolls wound on cores up to 150mm. The second system will produce gusseted tube ﬁlms with a 7 metre circumference in a thickness of 10 mm and other widths to 40 mm. This machine will wind rolls of 1 200mm in diameter on a Model 1580 winder.

WORLD NEWS

IAC Group (Luxembourg: Daniel Eberhardt Environmental Stewardship Award for extensive use of recycled plastics in automotive interior components; reducing energy consumption and large reductions in waste going to landﬁlls.

THE district of Bad Dürkheim in Germany has approved the permanent use of organic waste bags made of BASF’s compostable plastic Ecovio® FS. Residents and local waste management companies tested the bags over three months and the organic composting plant rated the results of the pilot project very positively. The bags made of Ecovio FS degrade completely and do not impair the quality of the compost. At the beginning of the project in April, the 65 000 households in the district each received 10 bags made of the compostable plastic Ecovio FS. The residents were encouraged to collect their organic garbage in the bags and to dispose of them via the organic waste bin. An independent consulting company monitored the pilot project and analyzed the compost at the organic composting plant. The residents were also surveyed about their use of the bags. The biodegradable plastic Ecovio FS is made of the partially bio-based plastic (polyester) Ecoﬂex FS and PLA (polylactic acid), which is obtained from corn starch. www.ecovio.de

Integra’s customized system includes a Davis-Standard Vertex die with increased IBC capacity and Triple Lip air ring

www.davis-standard.com

BOOKS

Long-ﬁbre PP compounds drive automotive innovation

Mixed fortunes for the world’s compounders

IN A NEW REPORT RECENTLY PUBLISHED BY AMI CONSULTING THE USE OF LFT PP (LONG FIBRE THERMOPLASTIC POLYPROPYLENE) IS EXAMINED IN DETAIL.

Instrument panel carrier for the BMW7 series made with Borealis’ 20% LFT-G PP Nepol grade (photo courtesy Borealis AG)

THE report quantiﬁes the use of both granule LFT PP (LFT-G) and direct compounding and moulding in-line of LFT PP (LFT-D) tracking down its use vehicle by vehicle around the world. The result is a comprehensive analysis of LFT PP by application, OEM and geographical region. Since the late 1990s two new families of PP based products have been gaining an increasing role in automotive design: LFT-G and LFT-D. LFT-G (Long Fibre Thermoplastic PP) refers to a product sold as a granule,

whereas the name LFT-D is used to describe the process in which an LFT is compounded and moulded in-line or directly. LFT PP is now used widely in automotive front end carriers, instrument panel carriers, door panel supports, consoles, pedals, under body shields and a number of other applications. The exciting feature of many of these applications is that LFT PP is permitting automotive engineers to either replace steel and thereby reduce weight and improve fuel efﬁciency, or replace more expensive engineering plastics. An example of a LFT-D PP moulding of under body shields made by Polytec for the VW group (photo courtesy Polytec Holding AG)

www.amiplastics.com

Analysis of the pigment market MORE and more manufacturers improve their packaging and promotional items by using modern colours and visual effects. Ceresana Research’s newly updated first in-depth study on the global pigment market has just been released. Ceresana expects that pigment revenues will increase to more than US$45 billion by 2018. In 2010, the Asia-Pacific region was responsible for 45% of the global demand for pigments. The secondlargest market was North America, followed by Western Europe. Ceresana anticipates that the Asia-Pacific will continue to significantly influence market dynamics in future. The rapidly developing emerging markets have the greatest growth potential, above all China and India. Moreover, South America and the 94

DECEMBER 2011 / JANUARY 2012

Middle East register aboveaverage growth rates of 3.6% to 4.4%. The new study contains more than 1 000 pages providing comprehensive analyses of the global pigment market. The 18 most important countries are analysed in detail, including relevant market data on the individual fields of application. A useful introductory chapter summarizes the most important information on the different types of pigments, their classification, properties, raw materials, production, application areas, and legal situation. The study is also a useful list of producers that includes 303 profiles of the largest pigment manufacturers.

www.ceresana.com

THE effect of the global recession on the thermoplastics compounding industry around the world is documented in a series of reports published by plastics industry consultants, Applied Market Information Ltd. (AMI). While the industry continues to surge ahead in Asia and Latin America, the European market has been through a period of shrinking demand that has seen compounders reorganise their operations. A 5% drop in the number of compounders listed in AMI’s guide to the thermoplastics compounding industry in Europe illustrates some of the effects of the recession on compounders in Europe. With the market having shrunk by 1 million tons between 2006 and 2009 it is perhaps surprising that the decline in numbers was not even greater. Production of compounds recovered in 2010 and amounted to nearly 7.6 million tons. AMI’s analysis shows that the structure of compound production also varies by region. In Asia colour compounds are more widely used while masterbatch accounts for a much smaller share of production. PVC compounds share a similar standing in all markets while engineering polymer compounds are more signiﬁcant in the Asian and European markets. www.amiplastics.com

Advertisers: DEC 2011 / JAN 2012 Advanced Polymers 03 Afritrade 22 Annecat 32 BASF 01 Cabletech Marketing 33 Carst & Walker 57 Chemimpo 58 Croda 17 Dema Plastech 53 DH Polymers 78 Hestico 48 Hosaf 54 Hume Machinery 79 IDC 77 Jenowill 81 Karbochem 87 Maritime Marketing 27 Masterbatch SA 63 MBT 60 Mercury Plastics 75 MGMW Trading 34 Miracle Mould 36,37 MJH Machine Tools 38,39 Mouldplas 29 Nissei ASB 21 Orion Engineered Carbons 25 Performance Colour Systems 85 Plasquip OBC Plastamid 83 PlastiChem IFC Plasticolors 43 PlasticsSA 67 Plastindia 13 Plastomark 31 PMS Plastics 35 Polysaf 89 Protea Polymers IBC Rawmac 80 Relloy (Reiloy) 05 SAPY Colours 51 SES 73 Standex Engraving SA 78 Sun Ace 47 UTP Mould & Die 69 Welltec 44 West African International 76

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How to advertise To place a classiﬁed advert please Fax: 086 519 6089 or Tel: 021 712 1408 or E-mail: saplastics@iafrica.com www.saplastics.co.za

For Sale BXnX^lZ_` BD)/'9 BXnX^lZ_` B(/'9 BXnX^lZ_` B+,@ Jlg\idXjk\i JD0' 8iYli^ ),&*,&.' kf jki`g ]fi jgXi\j MXZlld cfX[\ij Dflc[ k\dg Zfekifcc\ij LckiXjfe`Z n\c[\i >Xi[e\i ;\em\i Zfdgi\jjfi )%) ZlY$d & d`e 7 / YXi ?fgg\ij DXk\i`Xc [i`\ij :fekXZk ;Xm\ Nfijc\p1 '/* ,/( )0/,

Sales Representative Basic + Com + car allowance 5yrs exp and proven track record within the plastics industry. A social company is seeking a young, dynamic, persuasive Sales rep with external sales experience. You will work towards a target, with occasional overseas travel as well as customer relations. Please send CV to keith@ mouldplas.co.za or contact Keith Reading on 082 458 7579

Machines for Sale ;\dX^ <i^fk\Z_ gif ,'$).' :cXdg ]fiZ\ ,' kfej Æ Df[\c (00. ;\dX^ <i^fk\Z_ ,'$).' :cXdg ]fiZ\ ,' kfej Æ Df[\c (000 :fekXZk1 E`\c fe '/) .*( /,(+

Film Blow Technician +5yrs exp in ﬁlm blowing machine setting and start up procedures Looking for a young, energetic individual to join a fast growing company to fulﬁll the position of Film Blow technician whose willing to do overseas travel for client and machine approval. Must have experience in multilayer co-extrusion, GEO-membrane as well as technical aspects. Remuneration package negotiable Please send CV to keith@mouldplas.co.za or contact Keith Reading on 082 458 7579

PLASTIC WANTED JCL Plastic Enterprises requires the following post-industrial materials for recycling: GPPS PVC-U PMMA

HIPS ABS PP PVC-P PC HDPE PE/PA POM PA Contact: Colin Ph 011 894 3520 | Fax 011 894 7284 | E-mail jcl@jcl.co.za or visit us at www.jcl.co.za

MALTA RECYCLING High-quality recycled HDPE, LDPE, PP, HIPS phone Steve tel: (021) 931 9658 fax: (086) 212 7270

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GREENLAND OILS Michael Engels 072 125 4323 Tel: (011) 903-8084 Fax: (086) 665-4323 email: mengels1@ telkomsa.net PO Box 1220 Walkerville 1876

DECEMBER 2011 / JANUARY 2012 95

SPORTS

A safe bet Kip Carbone helmet can withstand multiple impacts A PROTECTIVE helmet for extreme sports fanatics has been designed by Va2or using Apro expanded polypropylene from JSP. The Kip Carbone helmet is lightweight and according to the manufacturer can withstand multiple impacts. Quentin Henquel at Va2or said: “As experts in sliding sports, we know from experience how important safety helmets are. We found with Arpro a material ensuring enhanced protection – a valuable beneﬁt to the wearer. “The Kip Carbone helmet has been developed as the ﬁrst multi-purpose,

ultra-light helmet for sliding sports. Whether on the snow or on the water, this helmet combines optimum comfort, protection, versatility and aesthetics.” Paul Compton, JSP president and CEO for Europe, Middle-East and Africa, added: “A crucial advantage of Arpro is the repeat impact performance available – performance not provided by polystyrene and polystyrene blends. Many extreme sports are extremely demanding on protective equipment and multiple impacts are common.” www.va2or.fr

Gyrocopter passion GYROCOPTER flying might not be everyone’s idea of fun, but for some, like Roy Miller of the injection moulding operation Miller Methods, it’s what keeps him young! Initially Roy started his flying passion on hang-gliders. “It was great fun and totally exhilarating, however, I didn’t enjoy landing miles from anywhere and having to trek long distances back to base,” he explained. The hang-glider now shares space in the hangar with Roy’s latest passion – a gyrocopter! A gyrocopter, also known as an autogyro (from Spanish autogiro), gyroplane or rotaplane, is a type of rotorcraft which uses an unpowered rotor in autorotation to develop lift, and an engine-powered propeller, similar to that of a fixed-wing aircraft, to provide thrust. While similar to a helicopter rotor in appearance, the gyrocopter rotor must have air flowing through the rotor disc to generate rotation. Invented by the Spanish engineer Juan de la Cierva to create an aircraft that could safely fly at slow speeds, the gyrocopter was first flown on 9 January 1923, at Cuatro Vientos Airfield in Madrid.

DECEMBER 2011 / JANUARY 2012

SA Plastics magazine’s Lowrie Sharp and Roy Miller all suited up and ready to roll