SA Plastics, Composites & Rubber

IT’S A FIRSTR!

YESTE TRITAN COPOL N FREEDOM ALLOWS DESIG

Technical hints: MOULD SAFETY

SERVO

BREAKTHROUGH

BY SES Like a second skin!

OFFICIAL PUBLICATION OF THE PLASTICS CONVERTERS ASSOCIATION (PCA) & PLASTICS INSTITUTE OF SOUTHERN AFRICA (PISA)

Credit insurance: Provider’s view Ren-Flex starts up

8

Reduce your electricity costs

64

Biogas from spaghetti?

100

re-SHAPE your thinking Tritan™ BPA-free copolyester will surprise you. It’s a significant and welcome breakthrough that helps you differentiate your products through design and performance.

Markets include: Houseware / Small Appliances / Medical packaging / Infant care / Sports bottles / Bulk water bottles

TRITAN™ is a registered Eastman Chemical Company product.

Tritan™ retains the versatility of copolyesters. But it also can offer unexpected advantages, including higher temperature resistance, easier processing and higher impact resistance.

Tritan™ reshapes your expectations of polymers. The unique properties of Tritan™ deliver performance that is often superior to other clear thermoplastics, such as polycarbonate (PC). Areas of potential advantage include ease of processing and lower levels of residual stress, as well as clarity, toughness and chemical resistance of the finished products.

For more info call 0800 006772 or visit www.plastichem.co.za

The PTA utilises temperatures hotter than the

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This unit delivers the latest technology in microplasma welding.

Relloy have been aligning themselves with the latest developments in the European market in order to provide European quality in the South African market.

RELLOY S.A.

(Pty) Ltd

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

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

BY THE WAY ...

PVC cling film article

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

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

www.saplastics.co.za

GAUTENG Lowrie Sharp t: (011) 793 4691 f: (011) 791 0544 c: 082 344 7870 e: lowrieplasticsmedia@absamail.co.za KZN Lynne Askew t: (031) 764 2494 f: (031) 764 0676 e: lynne@leafpublishing.co.za Europe & UK Eddie Kania RGH International, High Peak, England t: +0944 1663 750 242 e: ekania@btopenworld.com Printed by: Tandym Print, Maitland, Cape Town SA Plastics Composites + Rubber Technology is published six times a year and focuses on these industries in South and southern Africa. We welcome news, articles, technical reports, information in general and photographs about events and developments related to the plastics industry.

The views expressed in the magazine are not necessarily those of the publisher. Views expressed are not necessarily those of the Plastics Converters Association, Institute of Materials or Association of Rotational Moulders either.

Copyright: All rights reserved.

ISSN number: 1684-2855 (ISDS Centre, Paris) Summit Publishing: CK 9863581/23 VAT reg: 4600187902

THE article in our last issue about PVC and the plasticisers and additives employed created some controversy. A large amount of attention has been focused on PVC cling film in the public media and it’s been blamed for a variety of health problems, but you need to ask if the castigation of PVC cling film has There are so been exaggerated? There are so many armany areas of eas of modern life besides which can cause modern life health problems. besides which Some positive points have come out of the ‘debate’ so far, specifically that the can cause heating of PVC film when in contact with health problems. foodstuff is unadvisable. Due to the complexity of the situation, we are on advice, not publishing our follow-up report here, but will do so in October.

All risks: Check your insurance MOST of us know by now of the dangers of cable theft, but losses incurred could be substantially more than just that of the cable ... and which quite possibly are not covered by your insurance. Two Cape Town converters received such an unwelcome surprise recently. Damage to stalled equipment and circuit boards, possibly caused during repair work, after cable leading to their plants was stolen, resulted in significantly higher claims – which were not covered in the ‘All risks’ section of their insurance policies.

So it may be useful to simply check with your insurance company or broker whether you are effectively covered. Do it now!

Caution necessary PREVAILING market conditions have placed most manufacturers under pressure and most of us are looking at ways at improving systems and efficiencies, but spare a thought for those with high debt levels. Being cautious is obviously necessary, but nothing would happen if we all practised extreme caution all the time. Tempering caution is sometimes necessary to get a business operation going, but this should become less necessary as a business matures. Unfortunately this does not always apply, and the current climate has badly exposed some over-optimistic businessmen. In one case we celebrated an MBO at a packaging manufacturing business … until we heard what financial committees the buyers faced. With large sums coming off the bottom line every month, there was little chance of success. The business has since crashed and burned. Most of us will sympathize, but also remember that optimism and reliable financial planning are at opposite poles.

Plastics|SA, supported by the paper and packaging industry and under the auspices of PACSA and the Waste Management Plan developed by the Recyclers Action Group (RAG), has launched a new student design competition aimed at improving the transportation of recycled materials in urban and rural environments. Although this photo is just an example of what’s possible, try and come up with a solution that is suited to southern Africa.

More info at www.plasticsinfo.co.za

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

METHING HAVE SO … IF YOU TO SAY de: if you e bright si Look at th wisdom to e gem of m so ve ha e to us at ease writ impart, pl frica.com ia s@ tic saplas

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

Volume 10 No 4

AUGUST – SEPTEMBER 2012

Contents

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

Type 90 Smart Temperature control units for water up to 90°C UĂŠ ÂœÂ˜ĂŒĂ€ÂœÂ?Â?iÀÊ,/ĂˆÂŁĂŠ*

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INDUSTRY NEWS Servo breakthrough by SES

6

World PVC markets recover

8

Thailand’s PTT builds ties with African convertors

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ASSOCIATION NEWS ARMSA: Rotation 2012 in September

28

IOM: Tangential mixer technology developments

30

PISA: Cape toolmaking training programme

33

FEATURE More than just PE & PP produced in Middle East

44

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TRAINING 50 year old research helps create

Type 150 Smart

46

new separation technique

88

DESIGN Tritan thermoplastic copolyester from Eastman

s 3IMULTANEOUS READOUT OF TEMPERATURE set-point and actual value

52

s #LEAR ARRANGEMENT OF OPERATING AND indicating elements

DIARY Events coming up in 2012

108

SPORTS Solar Impulse to attempt ight to Africa

112

92

ON THE COVER JOBURG-BASED snapp Design’s ‘splay’ salad servers are the ďŹ rst plastic injection moulded product designed by the company. By using the extruded form of Plasticine and manipulating it and separating the blended proďŹ le forms into tines, snapp were able to create an intriguing and functional utensil.

Snapp approached Plastichem for their expertise and technical knowledge. The appropriate material that was deďŹ ned is a ďŹ rst for snapp and for South Africa as this particular thermoplastic has never been used commercially here before.

See page 52 for more information

s 3OLID STATE RELAY 332 INSTEAD OF heating contactor s !LL COMPONENTS EXPOSED TO WATER ARE made of non-rusting materials, hence long service-life s !CHIEVES ESTIMATED REDUCTION IN REJECTS AND INCREASE IN PRODUCTIVITY

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Plastics|SA’s new name and branding is becoming more visible. The previous entity, the Plastics Federation of SA, did not capture the imagination … specifically of consumers. Although it was mainly a name change to Plastics|SA, the industry’s ‘new’ association is proving to be a more holistic model and, in the name of our ubiquitous material(s), is becoming far more visible. The photo here was taken at World Oceans Day in KZN in June

THIS ISSUE

SHORT SERIES COLUMNS

TO INFORM

Martin Wells

, Publisher

Articles on competition law, credit insurance, technical hints for your benefit

COMMENT

L

IKE anything else, this publication is changing with the times.

We have somewhat unexpectedly become the recipient of interest from some service suppliers to the industry. That’s not to say we have not attempted to solicit information on topics which we believe are relevant to the manufacturing environment. These parties are offering to supply columns to us about industry matters, which has led to a slight change in focus for us, as we go about producing a publication which is relevant and useful to you.

In this issue we complete a series of articles about Competition Law from Adams & Adams, the Pretoria attorneys, that has proved highly interesting (page 48).

You literally cannot afford to be in manufacturing – or let’s even say operation – if you are not relatively well informed about competition legislation (and specifically anti-competitive behaviour). You could get caught up in affairs that are beyond control, or – even worse – be put out of business by anti-competitive behaviour.

And we have more for you!

Technical ‘hints’ We are fortunate this issue to be able to begin a series of ‘Technical Hints’ columns from some of the experts in the industry. It’s not often that the ‘experts’ are happy to impart with info, partly because they tend to be very practical people and don’t in the first place consider themselves to be ‘experts’. There are important areas of the industry where we can all improve, however, and that is the goal of this series.

We begin with a short column about mould safety from Bob White of Principal Plastics of Port Elizabeth

4 AUGUST / SEPTEMBER 2012

(page 20). The points Bob mentions are simple and easy to comprehend, and worth pursuing in your factory. Minimising the risk of injury to your workers is very important: besides injuries and trauma to staff, such events can hold up your whole operation.

There are important areas of the industry where we can all improve, however, and that is the goal of this series

Credit insurance While on the subject of risk, in this issue we are also publishing the first of a series of columns from Coface South Africa, one of the top providers of credit insurance to industry (page 50), about this vital topic.

Paul Jooste of Coface explains the logic and strategy applied. We hear of suppliers sustaining credit failures with alarming regularity, even after practicing caution.

Coface is a specialist in this area, and the points raised

by Jooste could thus prove useful to you.

Momentum from sports The Olympics will be a thing of the past by the time this reaches you, but South Africans – and all Africans for that matter – were buoyed by some positive international performances by our people on the eve of the event. It’s ironic that success or failure on the sports fields is now regarded with such prominence, when the same (success or failure) applies to most of the rest of us virtually every day.

cool houses love energy bills BASF’s construction solutions and energyefficient materials are more cost-effective than conventional insulating systems and materials, and have a much higher insulation capacity.

So, thanks to products like Neopor® and Elastopor®, houses stay cooler in the summer and waste less energy.

Saving on emissions means saving on bills? At BASF, we create chemistry.

www.basf.com/chemistry www.basf.co.za

JUST BRIEFLY BOXMORE COMPLETES MCG CLOSURES PURCHASE BOXMORE Plastics has completed its purchase of the MCG Closures business in a transaction valued at over R100-million, marking the start of a new phase for the business.

Boxmore has been in operation in South Africa since 1996, when it was established by its Irish parent. The company was subsequently bought by Chesapeake of the USA. A management buyout backed by Investec group took place in 2010, in terms of which the business has since been SA-owned. It manufactures preforms and blown bottles at plants in Harrismith, Cape Town and Mauritius, and needed the additional closure capacity to support those products.

The MCG operations, in Samrand and Cape Town, manufacture an estimated 2.5 billion closures p/a. These businesses are to trade as Boxmore Plastics Closures. Boxmore group currently supplies about 1.4 billion preforms. www.boxmore.co.za

KENIPLAS NOW AGENT FOR ADDITIVES SUPPLIER LIBERTY, OF INDIA KENIPLAS of Johannesburg has been appointed as the exclusive agent and distributor in Southern Africa for the full range of polymer additives manufactured by Liberty Chemicals of India. Liberty Chemicals is a leading manufacturer and exporter of polymer additives consisting of internal and external lubricants, functional additives, antistatic additives, processing aids, pigment wetting agents, dispersants, synthetic waxes and polypropylene clarifier.

Liberty’s pigments, fillers or other additives are used in the production or processing of PVC, LDPE, LLDPE, HDPE, PP, PS, ABS, EVA, PA, PC, ABS, PMMA or PET, and in fact in virtually any other polymers – in masterbatch or compound form in the injection, extrusion or blow moulding processes.

Capacity at Liberty’s state-of-the-art manufacturing facility is approximately 6000 tons per annum, which is high for such specialised materials.

The company is ISO 9001:2008 certified. www.libertychemical.com; www.keniplas.co.za

INDUSTRY NEWS

Servo breakthrough

by SES Johannesburg machine builder develops new servo system THE process of assembling and more recently building its own injection machines has had an unexpected spin-off for SES: it has developed a system which allows for a single servo motor to accomplish two movements during machine ‘dead’ time.

Servo motors are expensive and can be difficult to operate, but the SES breakthrough allows for users to gain more performance per motor. Using a single servo motor with a servo pump, Karl Seidel and the technical service team at SES developed a system that can achieve parallel movement with separate speed and pressure from the one motor.

The system allows users to gain more usage per servo motor. According to Karl,

HAT-TRICK

for Principle Plastics Auto component supplier wins series of supplier awards

EH WALTON CLOSES E H Walton, one of the oldest and largest privately-owned printing and packaging companies in South Africa, has gone into liquidation. Based in Port Elizabeth but selling nationally, was established in 1845, when it printed the local newspaper. It had made significant investments over the last few years, estimated at over R22-million, in order to be more competitive and the announcement of closure in April came as a surprise. The company employed about 450 people in PE.

BASF OPENS NIGERIA OFFICE BASF has opened a new regional office in Lagos to serve customers in Nigeria and the other West African countries, further increasing its presence in the growing African markets.

The company’s target is to more than double sales in Africa by 2020.Sales, excluding oil and gas, were around €1-billion in 2011.

6

AUGUST / SEPTEMBER 2012

the breakthrough has created “the platform for the next development”.

Additional tasks that can be performed by the configuration include: • ejector while opening; • core pulling with mould movement.

Johannesburg-based SES, which is the SA agent for injection machine manufacturer Ferromatik Milacron, has also become one of SA’s leading machine refurbishers, particularly of the older Ferromatik modules, and in 2010 it introduced its own machine, the ‘SKR’. Activity at the SES workshop in Wadeville has at times bordered on the feverish, with ‘hands-on’ MD Seidel and Daniel Roode constantly looking for ways to improve technology

Bob and Niko White have been putting lessons learned over many years to good effect at Principle, the main result being the company’s growing ability to supply automotive OEMs in a convincing manner

PRINCIPLE Plastics, one of the top automotive component manufacturers in the Eastern Cape, has been receiving recognition for its high-level supply. It has won three ‘supplier of the year’ awards in recent months, from Behr Climate Control, General Motors and VW. That’s a just reward for the team assembled

by Bob and Niko White, the father and son outfit who run the business in Markman Township, Port Elizabeth.

Principle was started by Niko White in late 2004, when moulding operations began with just two machines. At that stage, operating from Neave, the company did not have the capacity to supply automotive contracts and survived on small custom contracts, but how things have changed! Niko was later joined

by Bob. The demise in late 2009 of what was Ariston Plastics, where both Bob and Niko had previously worked, presented an opportunity for Principle: it moved from Neave to the Ariston site at Markman and quite literally took over where Ariston had left off, resuming supply to

and develop systems that are suited to South African conditions.

The process has been partly driven through SES’s cooperation with a top Austrian automation systems developer. B&R IndustrieElektronik is a master at electronic control technology, said Karl, and working with them has enabled SES to cross-refer in ‘real time’ and hence pursue these challenges at a higher level. Karl says, however, that the servo development is unique to SES. www.sescc.co.za

Daniel Roode and Karl Seidel of SES with one of the company’s SKR injection moulding machines with the new single servo motor system; SES has also designed its own control panels to accommodate the new software features it offers.

With the new SES system, mould heater settings are included with the mould setting data, which makes it easier for the setter to switch moulds and be back in operation sooner

JUST BRIEFLY CLEAN-UP YOUR ACT! THIS year’s Clean-Up SA week takes place from 10-15 September, when you have a chance to help improve the public image of plastics by getting involved in clean-ups and other environmental activities.

Find out more at: www.cleanup-sa.co.za; www.recyclingday-sa.co.za

SACU-INDIA TRADE DEAL: ALL QUIET Tug o war! This is what staff at Principle Plastics in PE do during their lunch break … err, not quite, but the production team did celebrate their most recent supplier award in a competitive way

the OEMs. Although getting the business to settle down was challenging, the Principle team haven’t looked back since.

better knowledge of their customers’ needs, which required experience and very specific analysis.

“JIT isn’t realistic,” said Bob. “We have to have JIT isn’t realistic a stockholding, and Part of Principle’s Our approach has been building that up has approach has been to to move away from the allowed us to have move away from the just-in-time (JIT) strategy more consistent just-in-time (JIT) stratwidely practised in the production runs. At egy widely practised in the same time, it’s the automotive sector. automotive sector. also allowed us to JIT implies that the dereact quickly in the unexpected ‘X’ factor sired part arrives at the auto assembly line situations,” said Bob. at just the right time, but according to Bob, Principle has also focused a lot of reit was, ironically, having the effect that parts sources on training, and conducts in-house were only being manufactured on a JIT training on a weekly basis. basis too. This resulted in numerous mould changes being necessary. The analysis they applied, in cooperation with their automo• PRINCIPLE PLASTICS, PHONE 041 461 2952. tive customers, meant they had to have a

THE Department of Trade and Industry has made no decision on the proposed SA Commercial Union-India trade agreement.

The Indian Government had requested that plastics, chemicals and cosmetic goods from India either be exempted from import duties or get preferential rates. Local companies involved in those sectors, not surprisingly, reacted negatively to the proposal. A survey was conducted by the DTI, where manufacturers were requested to list objections by 12 April, and – although it’s not known how many reacted – the DTI had made no decision by the end of July.

MBO AT JOJO A CONSORTIUM consisting of key management members, RMB Ventures, RMB Corvest, Pan-African Private Equity Fund 1 and the Oppenheimer family’s Stockdale Street private equity vehicle have concluded a management buyout of JoJo Tanks.

JoJo Tanks is South Africa’s leading manufacturer of roto-moulded polyethylene tanks used for rainwater harvesting and general liquid storage. www.jojotanks.co.za AUGUST / SEPTEMBER 2012

7

INDUSTRY NEWS

World PVC IML markets recover manufacturer Ren-Flex 36 million tons global consumption in 2011 is highest ever

business internationally,” said Van Eyk. INTERESTING statistics about trends in “Mitsubishi Corporation is a key partner the global PVC market were presented at to our business and strategy,” he added. the Sun Ace Group annual board meeting The decline in PVC consumption in in Japan recently.

North America, which has in recent years World demand for PVC reached a become a nett exporter of PVC resin, record high of 36 million tons in 2011, together with the decline in Europe has showing a recovery from the previous high of 35 million recorded in 2008, before been counterbalanced by major demand increases in the Asian region. Other the global financial crunch. Another very markets showing noticeable trend particularly strong was the slowThe observation drawn by demand include down in growth in the Mitsubishi analysts is Russia and Turkey.

China, which in Consumption in 2010 showed a that the PVC sector is set both Russia (at dramatic increase of to grow at an estimated 1,11 million tons in 17% – that declined 3% rate in 2012, and 2011) and Turkey to a more manageinto the near future.

(920,000 tons) able 7% increase in exceeds total andemand last year. nual demand for the African continent, The figures were presented by Mitsubiestimated at 872,000 tpa. shi Corporation at the Sun Ace Group Outside of South Africa demand in Afmeeting in Tokyo in June. Mitsubishi, rica is highest in Algeria and Nigeria, both which trades in excess of 1million tons of of which exceed 100,000 tpa. Although PVC resin annually, is one of the Sun Ace demand for PVC is increasing steadily Group shareholders. in Africa, by comparison it equates to Gary van Eyk of Sun Ace South Africa, approximately only a third of the Central a leading supplier of additives, processing and South American demand, where 2,6 aids and manufacturer of stabilizers to the million tons was used in 2011 representvinyls sector across sub-Sahara African ing approx 25% growth over the past four markets, represented the local interests at years in that region. the board meeting.

The inference of the Mitsubishi figures The observation drawn by the Mitsubiis that although consumption of PVC in shi analysts is that the PVC sector is set Europe and North America has declined, to grow globally at an estimated 3% rate total global consumption is still increasin 2012, and into the near future. ing – and this is creating opportunities for “Whilst the Sun Ace Group does not global scale manufacturers, particularly trade in PVC resin, the insight into world those in the USA. markets, trends and trade balances directs our resources and focus into www.sunace.co.za markets and applications that benefits our

Sun Ace board members hosted at Mitsubishi Corporation head office in Tokyo, Japan, recently include Hanada-san of Mitsubishi, Ian Lilja (MD of Sun Ace Australia), Gary van Eyk (MD Sun Ace South Africa), Dr Ettore Nanni (CEO Reagens Europe) and Hamdan Al Hamdan (MD Sun Ace Saudi Arabia) 8

AUGUST / SEPTEMBER 2012

starts up High precision Drent-Goebel UV press used to make in-mould labels I WAS ONCE TOLD that when you are a printer you don’t exploit words that would try and convince potential customers of the print quality you promise ... if you are in printing, quality is the norm!

“However, producing a quality print at a world standard is definitely an accomplishment and doing this successfully on a BOPP/polypropylene material is definitely amazing,” said Albe Naudé, COO of RenForm, owner of the new IML producer RenFlex, of Johannesburg.

Ren-Flex has commenced production of IML, shrink-sleeve and wrap-around labels at its plant in Selby, Eloff Ext, Johannesburg. The entire factory is dedicated to plastic products only. Utilizing state-of-the-art printing equipment (it operates a 9-colour Drent-Goebel UV offset printing press, built in Korea) with off-line rotary die cutting capability gives Ren-Flex an advantage.

The management personnel is headed

by Patrick Munyembate (managing) and Vijay Gramoney (technical), both previously

Lanxess delivers learning material to rural KZN schools MORE than 2 000 children from 12 schools in the rural KZN south region recently received educational material delivered to them by Lanxess employees and other partners during this year’s annual Rally to Read event. The material, which included 50 box libraries, sports equipment, educational toys, school bags and stationery, was delivered after a team of Lanxess employees together with other corporate partners travelled over 350km from Durban to rural KZN South. McCarthy car dealership, one of the major sponsors of the rally, provided the team with off-road

The Ren-Flex team includes MD Patrick Munyembate, print manager Dwayen du Sart and technical director Vijay Gramoney

employed by FIMA. Critical product issues experienced before will be avoided by implementing the experience gained over the years, including but not limited to static, film densities and product behaviour in different environments.

Ren-Form has since its establishment in 1989 been a highly successful printer of commercial forms that has since evolved into the digital print-on-demand and highly sophisticated security printing areas. Due to Ren-Form’s revolutionary and technological vision, it was only a natural migration to apply technological excellence onto different substrates and markets, added Naudé.

As the first IML products rolled off the

production line, quality in print, finished size and presentation was noted as impressive.

End users, injection moulders and graphic designers will be excited to meet the team and expand on their current capabilities.

• REN-FLEX, PHONE 011 499 1207.

• PARENT COMPANY REN-FORM ALSO PRINT LABELS AND TICKETS FOR AIRLINES, THE LOTTO AND PRODUCTS FOR A VARIETY OF SA’S TOP BRANDS, INCLUDING MTN AND STANDARD BANK.

www.ren-form.co.za

Schober die-cutter for the production of the IML products; IML label films are typically about 60 microns thick

Attempt to refloat Petzetakis MEMBERS of the international management team of Petzetakis group of Greece held a press conference at PlasticsSA in Midrand in June at which they outlined a strategy to revive Petzetakis Africa. The focus of the event appeared to be to map out a course to appease creditors.

Activity at the Petzetakis plant, which had been one of the biggest pipe manufacturing businesses in southern Africa, has been at a standstill since February 2011, and staff have departed.

Dr Mohamed Hammound of Concritech of Australia, which has since bought a stake in Petzetakis, led the presentation. Concritech is involved in major international construction work, including several projects in the Middle East. George Petzetakis, chairman and CEO of Petzetakis in Greece, was also present. vehicles for the trip. According to Lanxess representative for South Africa, Dr KarlRudolf Gassen, the initiative is one that Lanxess South Africa is privileged to support as it responds to a tangible socioeconomic need in the country. www.lanxess.com

Dr Mohamed Hammoud, group MD of Concritech (Australia); George Petzetakis, CEO of AG Petzetakis group of Greece; attorney Kevin van Huyssteen; and Aris Sarlis, sales manager at Petzetakis in Greece AUGUST / SEPTEMBER 2012

9

PLASTICOLORS

Established 1976

Extraordinary

black

[PlastiColors now offers Hubron Black Masterbatch in partnership with Banbury Chemicals]

Innovation. Agility. Focus. In keeping with our emphasis on customised solutions, Plasticolors now offers world-class Hubron Black Masterbatch in convenient, smaller quantities.

As leaders in masterbatch, pigments, liquids and additves, our single-minded pursuit of perfection in colour will keep your business in the black. www.jhafrika.co.za 23396C

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

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Consistent and quality masterbatches from

Consistent black masterbatches from

Purging compound from

Accurate dosing machines from

PET Colours (microgranules) from

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INDUSTRY NEWS

CLEVVA … from novice to experienced, quickly Mobile ‘hands-on’ coach offers the right solutions, no matter what the situation SOMERSET West-based CLEVVA, a hosted Software As-A-Service (SAAS) business, may just have cracked the proverbial code when it comes to overcoming human shortcomings, and lack of business and product knowledge with the help of mobile technology.

Launched in April this year, CLEVVA is a mobile technology which essentially automates all standard operating procedures and gives the user access anywhere, anytime, enabling them to access information that allows for consistent decision-making and implementation, considers all variables and if necessary, guides them through diagnostics.

The key to CLEVVA lies in being able to capture the knowledge held in a few experts’ minds and organise it so that new and existing staff can use it.

We asked Ryan Falkenberg, cofounder of CLEVVA, how this can be done without new or existing staff having to personally learn through years of hardearned experience and training courses.

And how do you ensure that when your key experts retire, the business does not feel the pain?

Falkenberg explained that previously answers lay in offering more training, more documentation and more coaching. “We used a variety of systems to manage this journey in the hope that we could limit the risk of inexperienced staff in our business. This includes using various e-learning and knowledge management systems. In truth, none of these attempts have really worked, and even with the availability of mobile technology, research has shown that staff members don’t often access these systems while they work.”

CLEVVA is the brainchild of brothers Ryan and Dayne Falkenberg (right) and their business partner Mark Pederson. These three successful entrepreneurs have already made a name for themselves internationally, each in their own areas of specialization and focus, but have now pooled their resources to deliver a home-grown solution for companies and the first of its kind in the world 12

AUGUST / SEPTEMBER 2012

“CLEVVA is a viable alternative, one that can be used by small, medium and large businesses to capture the decisionmaking logic of their experts in a way that really helps inexperienced and undertrained staff to perform like experts,” he added.

Falkenberg explained that this new breed of technology guides staff through key activities, asking the right questions, and offering the right solutions, no matter what the situation. CLEVVA allows companies to capture the expert logic required to analyse various challenges, and then provides inexperienced sales staff with an expert guide. All the user needs to do is answer the questions; the rest is taken care for them.

Guides staff through key activities Flipping open his iPAD, Falkenberg demonstrated how anyone could effectively sell a wide range of technical flooring products without requiring any product knowledge. The system guides the needs analysis, recommends the right products, cross sells related products and allows you to generate the quote or order right there and then.

“The technology works with any form of mobile technology, including laptop computers or smart phones and integrates seamlessly with your existing financial and CRM systems. Sales and support teams can now perform with the comfort of having all the business intelligence and expertise at their fingertips”, he

explained.

Before it had even officially launched or raised its public head, CLEVVA had already received international recognition for its ability to transform and revolutionise the traditional approach to business. It was recently selected as a high impact South African business by Endeavor in 2012, a global non-profit organisation that identifies and supports innovative, high-growth entrepreneurs in emerging markets such as Argentina, Brazil, Chile, Colombia, Egypt, India, Mexico, South Africa, and Turkey. It has also successfully signed up clients in various fields and industries, including FMCG, flooring, building and construction and even commercial banks and local government and service delivery companies are eager get in on the action.

“Because CLEVVA makes it easy to capture the decision-making capability of an organisation’s few experts, staff can successfully be performing activities in a very short time that previously required a number of years of experience to tackle. That means business can now scale their expertise without the long lead times of training and experience on the job. People can achieve more, with less risk and less training. Now that is a game changer”, said Falkenberg.

www.clevva.net

INDUSTRY NEWS

Thailand’s PTT builds ties with African convertors 3-million tpa polyolefins supplier hosts get-together southern Africa market, was presented

by PTT and its suppliers at the Hyatt Regency Hotel in Rosebank, Johannesburg, on 31 May. The aim of the seminar, which was Now we’ve found out what their secret attended by convertors from across recipe is: not only are they good cooks, southern Africa, was to show PTT’s comthey’re also very successful businessmitment to the local market as well as for men who have a habit of implementing their sales and support team to familiartheir strategies very ize themselves with effectively. the regional market, PTT to commence One of the best said Trevor Moroney, manufacture of examples of Thai local manager for NatureWorks range business acumen Emeraude group. of naturally sourced is the PTT group, PTT’s additional the country’s leadpolymers in Thailand objective was to ing petrochemical inform converters business. PTT, the Petroleum Authority of the new range of bio polymers it supof Thailand, has been in operation since plies through its investment last year in 1978, sourcing feedstock from their own NatureWorks group, the USA/German gas reserves in the South China Sea. manufacturer of PLA-based and other It has been increasing polymer producnaturally sourced polymers. tion steadily: PTT Polymer Marketing Company currently supplies about three Tonnages million tons of a range of polyolefins per annum.

PTT’s present output figures are formiIt has become a leading supplier to dable, including convertors across Africa through its dis1.2 million tons per annum of PP tributor, Emeraude group of France. For 800,000 tpa of HD its Africa business, Emeraude operates 400,000 tpa of linear-low offices in Johannesburg, Algiers, Cairo 300,000 tpa low-density and and Lagos; servicing the African markets 90,000 tpa of polystyrene. from its regional HQ in Dubai.

Figures like this give PTT global One of PTT Polymer Marketing’s supplier status, and the PTT team are strategies is to host regional seminars backing that with a service oriented stratin its export-destination markets. The egy. It would appear that the series of seminars and visits to customer markets seventh such seminar, in this case for the

UNTIL quite recently most South Africans’ only connection with Thailand was through highly popular Thai cuisine.

1

1. PTT president Supachoke Liamkaeo, visiting from Bangkok, flanked by PlasticsSA CEO Anton Hanekom and Emeraude SA’s Trevor Moroney, host of the seminar

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AUGUST / SEPTEMBER 2012

2

2. Charles Muller of Astrapak, Lloyd Sharp of Unique Engineering, Zev Koffler of Rand Plastics and Lowrie Sharp of SA Plastics mag were at the seminar, and not in rush to leave afterwards either

have enabled PTT to react efficiently to market trends: it has consistently introduced grades for specialised applications, the most recent being a new HD grade for caps and closures. It has likewise tweaked material grades for roto moulding, monofilament production and thermoforming applications.

PE / PP market analysis PTT’s interest in Africa is based on the expectation that polyolefins demand is growing significantly: for example, stats suggest that an estimated 800,000 tons of HDPE will need to be imported into Africa this year alone. Demand for LDPE, LLDPE and PP appear to be large too.

The PTT strategy is based partly as a result of the West-inspired oil embargo of Iran. Since the Iranians have been major suppliers of oil and polyolefins into Africa, that the shortfall will have to be obtained from somewhere else.

‘Bio’ polymers PTT’s most recent introduction is a new range of bio polymers, using naturally sourced materials. A show of hands revealed that very few in the audience had previous experience of processing such materials, but in spite of this apparent lack of experience, the PTT speaker said it was clear that anti-plastic campaigns had occurred in many countries and suggested that it would be unwise to ignore

3

3. Emeraude team – Trevor Moroney of Emeraude SA and Emeraude group’s CEO, Umar Rafique, who is based in Dubai.

Emeraude’s head office is in Paris

Rothenberger donates plastic welding machine

The PTT Polymer Marketing team at the SA seminar included Thaiyaphat Jittiborripat (sales manager, Polymer Marketing DMCC); Chaipat Komolchaiamorn (GM Polymer Marketing DMCC); Narongchai Pisutpunya (executive vice-president: commercial & marketing, PTT Polymer Marketing), who was the main speaker; Supachoke Liamkaeo (president, PTT Polymer Marketing); Ms Somsri Phanichrungruang (vice-president: export sales, PTT Polymer Marketing); and Raqchao Chaowaraq and Apirasak Tregasonnoppamas (PTT area sales managers for the non-Asia region)

this trend. The campaigns against plastic bags, including levies and even bans, have led to a reaction from global brand owners, one of the most obvious presently being Coca-Cola group’s PlantBottle™ resins.

PTT made a major investment in world leading bioplastics manufacturer NatureWorks last year and is working towards supplying the family of renewable Ingeo™ biopolymers made from plant sources, the main application to date appearing to be thin-wall packaging containers and fibres.

A result of the NatureWorks investment is that a world-scale PLA plant is to be constructed by PTT group in Thailand.

PTT is currently also involved in a ‘bio chemical’ venture with Mitsubishi of Japan, as a result of which it is currently involved in the construction of a ‘Bio-PBS’ manufacturing unit in Thailand. So it’s clear that this is becoming a major focus for the group.

ROTHENBERGER Tools South Africa has donated a P160B plastics pipe welding machine to Plastics|SA to train the industry’s future pipe welders.

According to Steven van Zyl, national sales manager at Rothenberger SA, the donation is seen as an investment in the future of the plastic pipe industry.

“Specialist engineers (beyond first degree) are reportedly not produced in a quantity that is sufficient for the growth of the plastics industry. Similarly, at an operations level, plastics pipe welders and fabricators are also in short supply due to new competency demands arising from innovation and technological development. The availability of trained and experienced thermoplastics welders remains of critical importance to the industry”, he said.

Manjary Subiah, regional training manager (Gauteng) for Plastics|SA, said the P1608 pipe welding machine would be used in the Thermoplastic Fabrication training. www.plasticsinfo.co.za www.rothenberger.co.za

www.pttplc.com

ABOUT EMERAUDE EMERAUDE is a global distribution company which sources plastic raw materials from major petrochemical companies worldwide, and distributes these to customers around the world. Its head office is in Paris and it operates offices in Dubai, Johannesburg, Algiers, Cairo, Lagos, Lahore and Shanghai; enabling it to sell effectively in Europe, Africa and Asia.

The group has been in operation for over 25 years and is now supplying polymers to

4

4. Don Nellmapius and Jan Kruger of Pandrol with Brad Jay of Advanced Polymers and Tommie Mostert, also of Pandrol. Pandrol is a leading supplier to the railways and mines

customers in over 50 countries.

While providing financial security and volume ratability to upstream producers, Emeraude provide its customers with a reliable, efficient and regular supply of an extended range of plastic raw materials.

In South Africa, Emeraude is headed by Trevor Moroney, operating from an office in North Riding in Johannesburg.

www.emeraude-international.com

5

5. Les Whittal of Advanced Polymers, the Innoplus™ PE ex-stock distributor in South Africa, and Martie Weitsz of Emeraude SA and national secretary David Rule

Anton Hanekom, executive director (Plastics|SA), Steven van Zyl, national sales manager (Rothenberger), Rose Diedericks, head of maintenance (Rothenberger), Leigh-Ann Ackerman, inventory & marketing manager (Rothenberger), and Isaya Mtshweni, technical trainer (Plastics|SA) with the P160B which Rothenberger donated to Plastics|SA AUGUST / SEPTEMBER 2012

15

INDUSTRY NEWS

SARS demands back-payment for bag levy from ziplock importers Demands of over R6-million could finish off suppliers reference was added during the drawing up SA REVENUE Services (SARS) sprung of the original legislation, in 2002, at the time a nasty surprise on ziplock bag importers aimed at shopping bags. The distinction recently, demanding back payment of drawn was that shopping bags are regarded the plastic bag environmental levy from as ‘secondary’ packaging – namely for use a number of suppliers. Both the Cape by consumers to carry other purchased companies confronted face demands in items – as opposed to the region of R6-million ‘primary’ packaging, each.

Part of the problem for used for the specific The demands are the companies recently transportation of for the payment of the confronted by SARS goods. In the case of 4c per bag levy on the ziplock bank bags, imported shipments lies in the definitions in the use would be to of ziplock bags – the Act, namely that the carry coins. specifically bank ‘flat bags’ were imported Importation of bags – dating back under a different ziplock bags has to 2009 and possibly tariff heading. been a trend for some before. Such financial time, due mainly demands would to the fact that, since the manufacturing badly jeopardize the future of both these process is relatively slow, some of the SA enterprises. suppliers have not been able to develop Part of the problem for the companies an economically feasible model for their recently confronted by SARS lies in the production. definitions in the Act, namely that the ‘flat The Cape Town companies were bags’ were imported under a different confronted by agents from the SARS tariff heading. It appears that the ‘flat bag’ 16

AUGUST / SEPTEMBER 2012

office in East London, and a senior SARS subsequently said the ziplock bags were not levieable, but the sword of Damocles still hangs over the two companies, both of which also manufacture film and various other bags.

Sequel to 2002 legislation The scenario is a sequel to the plastic bag legislation of 2002, when the levy was introduced as an environmental measure aimed at reducing plastic bag litter and intended to help boost recycling of bags.

The fact that very little environmental work was ever completed appears to have had little bearing on the taxation authorities.

Besides that, the entity created to manage the process, Buyisa e Bag, failed to achieve the objectives set out and was shut in June last year. Buyisa had apparently received an estimated R65-million over the duration of its existence, but had not succeeded in its objectives. Total income generated from the levy is estimated at R150-million a year.

Big growth for PET wine bottles 350% increase achieved THE potential benefits of PET packaging for wine have been under the spotlight since the introduction of the new containers, in competition with the traditional glass bottles, in 2010.

Among the most common questions directed at Mpact Plastics group, which was one of the first to introduce the containers, by consumers centred on whether the “the quality will be the same”.

According to Jonathan Musikanth of Mpact, it has been proven that the PET bottle does not affect the quality and taste of the wine in any way. The design prevents the absorption of oxygen into the bottle, giving the wine a shelf life in excess of two years.

In economic terms, plastic wine bottles are on average eight times lighter than a traditional glass bottle. A PET bottle weighs 50g compared to its glass counter part’s 400g. This is an important advantage, meaning that up to 36% more product can be transported from a manufacturing plant to a retail outlet because the bottles require substantially less space and trucks can be fully loaded.

We asked Musikanth how the new containers have been faring:

How successful has the launch of these containers been, in terms of market penetration?

We have seen successful launches of several brands locally and for export in 750ml. Several customers have used our bottles including brands such as Backsberg, Boland, Simonsvlei and most recently Van Loveren. These 750ml bottles are available in many of South Africa’s major retailers, while the 187ml bottle has been successfully used on local flights such as SAA and international airlines. We have recently launched our new 1 litre bottle.

By how much have volumes increased?

Volumes have increased by 350% from 2011.

Have there been any new/further technology advances?

Since 2011 we started to use recycled content (r-PET) in our products. Currently 25% of the bottle is made-up of r-PET and together, with our partners, we are looking into ways of increasing this percentage.

The Wine & Spirit Board approved the use of PET for South African Wine of Origin certificate use in 2010, when one of the first varietals introduced was the ‘TreadLightly’ range of wines from Backsberg of the Western Cape

www.mpsa.co.za

AUGUST / SEPTEMBER 2012 17

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 years. We offer a comprehensive product portfolio, together with supply chain management, financial and technical support to the Rubber and Plastic industries.

Within the Polymers Division, the following business units provide the customer with the ultimate polymers solution:

ELASTOMERS

• ACM • CR • EPDM • Epichlorohydrin • FKM • HNBR • HTV Silicone • IR • NBR • NR • PVC/NBR Blends • SBR & BR

PLASTICS & COMPOSITES

• ABS • Acetal • Additives • Composites • CPE • CSM • EVA • HIPS & GPPS • Nylon • PBT • PC • PVC • TPE & TPV • TPU

FILLERS & ADDITIVES

• Aluminas • Antimony Products • Blowing Agents • Carbon Blacks • Flame Retardants • Hydrocarbon Resins • Magnesium Oxide • Masterbatches • MC & PE Waxes • Mineral Fillers • Peroxides • Process Aids • Rubber Chemicals • Silanes • Silica • Sulfur • Zinc Oxide

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• Curing Bladders • Machinery • Other Services • Release Agents • Release Liners • Spares

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• Anti-tack • Bonding Systems • Coated Powders • Factice • Masterbatching • Process Aids • Toll Manufacturing

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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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INDUSTRY NEWS

AfriMold

hopes to boost industry growth Stakeholders believe fair will boost industry’s international exposure KEY role players in South Africa’s tooling, precision engineering, mould making, design and application development industry are looking to the annual AfriMold trade fair to play an important role in supporting, growing and developing their industry.

The annual AfriMold trade fair takes place from 10-12 October at the Gallagher Convention Centre in Midrand.

Stakeholders are unanimous in their support of the fair and believe it will give a boost to an industry that, like so many others in this economy, is experiencing slow growth and could use international exposure and input to enhance its competitiveness and relevance.

Victor Stiehler of Hestico, supplier of machines, ancillary equipment and components to the plastic, rubber & packaging industries, elaborates: “The tooling industry is busy growing slowly but surely, however it will still take a while before it gets to the level that it can and should be at. The fact that the big OEMs go overseas to have tooling made there, rather than here, is a problem. The toolmakers in South Africa must rebuild trust with their customers so they can build tools for them again.”

Star Tooling is another exhibitor that believes AfriMold will add value to both the industry as a whole and to its business

Waste not, want not NAMPAK Flexible says it is currently producing some exciting results in the multi-layer plastics recycling arena through projects that focus on absorbing plastic waste from their operations.

Nampak Flexible recently activated a unique sorting and streaming system for all of its post-industrial waste to allow maximum recovery and reprocessing back into products through various technologies and processes. One process makes material available to NGOs where it is ‘up-cycled’ into a range of products that can be produced for customers. Examples of such products include bags, bowls, collapsible bins, benches and pallets to mention but a ‘few’.

Nampak Flexible is even using

technology to reprocess its own waste for reuse internally by making pallets that are currently being used in the company’s warehouses as an alternative to wooden pallets.

But the recycling of this waste is not just an environmental issue; there are social and economic benefits for NGO’s and local communities too.

Nampak Flexible is also looking ahead at opportunities to supply schools with injection-moulded chairs produced from post-industrial flexible waste; the company is already involved with a similar project supplying kids tables and chairs to crèches in the local KwaZulu-Natal area. www.nampak.com

AUGUST / SEPTEMBER 2012 19

in particular. Says the company’s Chris Schmid, “I think there is potential at a fair of this nature for industry players to identify and meet the correct partners, should this be the objective.”

Several industry players are also looking to AfriMold to support their initiatives to enter into joint ventures and partnerships with foreign companies.

Toolquip and Allied’s Maurice Lockwood points out that the main benefit of exhibiting at AfriMold is “because it is aimed at a specific area of the industry”.

The company will be using this uniquely targeted opportunity to exhibit a CNC machining centre, Baty 3D vision master camera based inspection equipment, CNC training simulator and small tools at AfriMold.

The AfriMold conference, which runs alongside the exhibition and is presented by the Tool Making Association of South Africa (TASA), will address the role of science in elevating current practice to the domain of leading economies. The conference will bring to its delegates a high level of technical knowledge, together with important issues such as production management; intellectual property and registered designs, effective business and legal contracts; global competitiveness; training; skills development; and employment creation. www.afrimold.co.za

Nampak Flexible KZN recently initiated their BAG4LIFE project and teamed up with the well-known Hillcrest Aids Centre. The first customer to participate in this project was Unilever; the result is highly creative, hand crafted and versatile bags that simultaneously promote some well-known brands and generate an income for those affected or infected by HIV or AIDS. This particular project creates employment for talented crafters who benefit directly from their work

TECHNICAL HINTS

MOULD SAFETY: Inter-related settings need to be considered

BY BOB WHITE, PRINCIPAL PLASTICS MOULD SAFETY, a very important part of setting moulding machines, is often neglected because it’s misunderstood.

Mould crashes are expensive and usually avoidable. To achieve optimal mould safety on machines, a number of inter-related settings need to be considered: 1) Position: To identify the correct position for the mould safety phase to begin, close the mould slowly and stop where you consider the safety zone should start. For instance, where angle pins enter slides, or where a part that hasn’t fallen out fully could jam. Input this position.

2) Pressure: Close the mould with the lowest possible pressure in the mould safety zone. This might sound obvious, but it’s surprising how many machines are not set properly in this zone. To ensure lowest possible closing pressure is set, it might be necessary to increase mould safety timer temporarily.

3) Speed: Set an appropriate closing speed. Closing too fast may not allow the machine time to react if there is an obstruction, and damage may occur even at low clamping pressure.

4) Timer: Set the timer to be just a fraction of a second longer than the actual clamping time (in mould safety zone) needed.

Some make the mistake of setting this timer according to the total mould closing time, which of course is much longer.

5) Re-check: Once all the above has been set, check again, as each adjustment affects the other settings.

To help explain mould safety on the shopfloor, ask whether the Setter would rather be pushed against a wall by a charging elephant, or a mouse?

Also, how long would he like the charging elephant to press?

Happy moulding!

dynamics of the Poor understanding of the dangerous mould zone can be extremely

INDUSTRY NEWS

Student design competition will explore rural transport Competition focuses on transportation of recycled materials in urban, rural areas AS PART of the International Year of Energy and the German South African Year of Science, Plastics|SA, supported by the paper and packaging industry and under the auspices of PACSA and the Waste Management Plan developed by the Recyclers Action Group (RAG), has launched a new student design competition aimed at improving the transportation of recycled materials in urban and rural environments.

The competition is open to students at Tshwane University of Technology, University of Johannesburg and Wits Engineering Faculty.

The objective is to ensure that the recovery of plastics packaging materials for recycling increases and to promote separation at source from households.

POLYCO, Plastics|SA and the Plastics Institute of SA (PISA) are sponsoring the Student Design Competition 2012. Entries should be submitted by 30 September and the winners will be announced in October at the Afrimold Exhibition at Gallagher Estate. It is envisaged that the winning concepts will also be exhibited at Euromold in Frankfurt in November.

The Fraunhofer Institute for Surface Engineering and Thin Films (IST) and the Fraunhofer Institute for Transportation and Infrastructure Systems (IVI) will provide students with the opportunity to engage with institutional specialists should their technologies be identified for incorporation in the concepts.

Concepts for mobility According to Douw Steyn, Plastics|SA sustainability director, there is a major need in the developing world in general and South African rural areas in particular, for a mode of transport for the rural poor to collect recyclable material and transport this to the collection station or depot, such as buy-back centres of recyclables.

“The SA plastics industry has made major inroads in the collection of plastic waste material and has

Is this a winning design? Entrants in the student design competition are encouraged to come up with concepts for mobility, be it human, electric, biogas or solar powered which could be a radical game changer in the developing world

established a recycling industry to keep these materials out of the waste stream. The project needs to be extended to the rural areas to prevent pollution and provide opportunities for entrepreneurs to establish themselves, providing this vital service to the community,” he adds.

Steyn said that entrants are encouraged to come up with concepts for mobility, be it human, electric, biogas or solar powered which could be a radical game changer in the developing world. The liberal use of plastics is encouraged, specifically if the concept mitigates mass manufacture and it needs to be light weight in construction.

“We encourage the lateral thinkers to analyse the problem and propose workable solutions. Clearly, athletics and functionality play a role, and the winners will differentiate their designs from the mundane!”

The following must be incorporated in the students’ overall project design and product: The use of plastics or plastics composites A mode of transportation capable of rural mobility Energy efficient Lightweight but capable of transporting up to 150kg Capable of mass manufacture Aesthetically appealing Must help plastics recycling recovery www.plasticsinfo.co.za AUGUST / SEPTEMBER 2012 21

INDUSTRY NEWS

Maritime open house 2012 Shows off A-to-Z blow moulding expertise, solutions MARITIME Marketing held its ‘open house show 2012’ at its premises in Kyalami Business Park recently, showing off its comprehensive blow moulding solutions and expertise.

Maritime has upped its supply to the blow moulding sector specifically with the recent addition of ISBM specialist John Craw to the team. John joins a blow

John Craw, who has recently joined Maritime Marketing, at the show with Stella Davis and Colin Fawkes of Castelco

Jeremy Mackintosh of Polyoak group flanked by Clive Corder and Jo Spohr of Maritime

moulding team already comprising Joe Spohr and Clive Corder. The trio operate from different basis – Spohr from KZN, Corder from the Cape and now Craw from Midrand – but also bring different specialities to the forum: Corder and his team specialize in machine building and also sell the machines of SIKA of Taiwan, which are becoming increasingly popular,

Fritz Strydom jnr and Fritz Strydom snr of Blomo Plastics with Jo Spohr of Maritime; Blomo manufactures children’s bicycles and polycarbonate water dispensing bottles

Peter Cawcutt and Clive Rautenbach of B&I Polycontainers

and Spohr has long-time international experience of extrusion blow moulding.

Craw, formerly at Nissei ASB, is one of the leading injection-stretch blow moulding experts in SA who has also been involved in this sector across Africa over the past two decades.

Together this team knows what works best in Africa!

Paul Visagie and Henk Visser of Mpact group with Bart Schurink of Maritime

John Craw and Yunis Khan of Mykas Plastics

EDM Shop show SURE First of Taiwan, principal of EDM Shop, is developing some very impressive high-speed metal cutting machinery. EDM hosted an open house show in July at which the new Sure First CM-565 system was demonstrated: the machine can cut steel at astonishing speeds of up to 30,000rpm.

Fine detail finishing work was being conducted on an injection mould at the show. www.edmshop.co.za

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AUGUST / SEPTEMBER 2012

High speed cutter – Agenderen Govender of Aztech, who demonstrated some of Delcam’s control and cutting solutions, and Les Porter of EDM Shop, with the high-speed Sure First cutting machine

Les also hosted Shane and Brandon Myburgh of Bellefield Tooling at the EDM/Weltec open house show in Chamdor in July

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INDUSTRY NEWS

Continental Compounders

A MEMBER OF

‘Quality in the making’ Agreement with Fainplast Italy to supply specialised halogen free, cross linkable, vulcanisate compounds & elastomers CONTINENTAL Compounders is in its 8th successful year of compounding PVC and has grown to become the largest PVC compounder in Sub Saharan Africa, supplying South Africa and deep sea export customers with over 22 000 tons per annum.

Customer service and product quality is of utmost importance to Continental and they have invested in a new specialised technical service laboratory for product testing and new product development for both local and international customers.

One of the founder members of SAVA (Southern African Vinyls Association), Continental fully supports the compelling drive towards international best practice for PVC products and processes.

These include: Safe use of additives, notably Heavy Metal Free (HMF) stabilisers and pigments Expanded recycling capacity and programmes Development of new and sustainable applications in PVC. “Europe’s Vinyl Plus and the Australian Vinyl Council have helped our industry to understand the future challenges and prospects in PVC. It is now up to us to raise our game and achieve those important standards and growth potentials,” said Continental Compounders MD, George Dimond.

“We have appointed a new and young executive management to enhance our

Continental Compounders’ crew – back: Hugh Hansen, Darren Van Rooyen, Brendon Soobramoney, Melanie Jones, Kholeka Mavundla, Karin Walters, Griffits Ngobese, Chuck Ramnath, Rodger Petre.

Front: Chantell Vieira, Slie Nene, Jerusha Keenan, Wayne Mollison, Desiree Naidoo, Meloshnie Daniel

existing experience in the organisation.

Wayne Mollison, Bsc (Eng) (Mechanical), has been appointed works director and Desiree Naidoo heads up our finance and administration. Rodger Petre has an expanded role with his team in sales, marketing and technical service,” he added.

Dimond said that Continental’s Parisbased export agent, Snetor Chimie, have assisted in developing Continental’s export platform into 25 countries primarily in Africa. Recently the expansion into South American markets has presented exciting export opportunities.

During 2012 the addition of three compounding lines will enhance the PVC compound capacity to over 30 000 tons.

Continental has signed a technical and supply agreement with Fainplast Italy to supply the industry sectors with specialised Halogen Free (HFFR), cross linkable and vulcanisate compounds and elastomers. These products will be stocked and supplied in South Africa to meet local and

Continental Compounders have invested in a specialised technical service laboratory for product testing and new product development for both local and international customers

international standards.

“These ambitious plans exist to give a quality product and service to our loyal customer base and keep Continental’s competitive edge in the industry,” said Dimond. www.compounders.co.za

MERSETA aims to train skills which add most value New project plans to improve grant system THE sector’s training authority, the MERSETA, is conducting a study of the industry aimed at improving the grant system and incentivising companies to train skills which will add the most value. The project is being managed by Plastics | SA “It’s a follow-up to the previous study on value chains and jobs in the industry,” said Christoph Vorwerk, who is leading the project.

“This is to ensure that we get better data

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AUGUST / SEPTEMBER 2012

from the industry in the workplace skills plans they submit to MERSETA. It will be done through email surveys and regional workshops to assist companies to complete the forms.”

A focus group session with some senior and influential industry captains is to be conducted too, in order to establish what the trends are and analyse how these will affect skills needs in the industry.

“Based on the above, the chamber will

be better positioned to design a grant system to incentivise the industry to train those skills which will add the most value. Also, the data on jobs will be used for a career guidance project,” said Vorwerk, who has been involved in industry training since the time of the PITB (Plastics Industry Training Board) in the 1990s.

He is being assisted by a skilled researcher.

• CONTACT CHRIS ON CVORWERK@ICON.CO.ZA

INDUSTRY NEWS

From far left: Solar powered vehicle using GP foams; Mould for solar vehicle, also produced with a GP foam; Boeing MEFA (manufacturing engineering fabrication aid)

HIGHLY SPECIALISED

PU foam formulator keeps it secret THERE’S a secret place at high-density polyurethane manufacturer General Plastics’ plant in the USA where no-one but employees sworn to secrecy is allowed.

That’s where the company formulates its highly specialised PU foams, materials that are used in some extremely high-tech and high-performance components.

With a history dating back to 1941, General Plastics (GP) makes highly specialised foams for the aircraft, composite lay-up tools and cores, marine, medical, thermal insulation, solar/wind energy, sport and other sectors. One of its most unusual products is Last-a-Foam® materials for insulation of nuclear containers, possibly one of the most demanding applications for foam yet.

GP began as a manufacturer of preservative coatings for wood and other organic materials and later expanded into fabricating phenolic-resin-impregnated composites for aircraft and commercial uses. It subsequently began producing coatings for fire hoses, through which it became involved in polyurethanes. Company founder LW Schatz saw an opportunity in specially formulating of PU material.

It began manufacturing foam blocks which could be used for a wide array of aerospace applications, and then began fabricating parts for high-performance structures. The latter is what attracted the attention of Graham Blyth of Aerontec of Cape Town: he noticed that GP had a grade of rigid or flexible PU foam for applications which in some cases were

previously unserviceable for the material, including composite core, blast mitigation, solar energy, signage, tooling and moulds and other markets.

Kirk Lider, head of sales & marketing at the USA company, recently visited South Africa as a guest of Aerontec and outlined some of their technology advances.

“We take the stress out of it,” said Lider,

outlining how GP’s foam structures have become increasingly application specific.

For example, it produces a foam for ice hockey sticks which have to absorb high impact hits, rigid PU board for the flight deck of the new Boeing 777 plane (GP material is Boeing-specified) and high-temperature tooling boards. In some cases the foams are integral skin, in other supplied in block forms.

With this kind of specialization, it is necessary for GP to keep its proprietary formulae confidential, hence the secrecy practised in the mixing section of its plant.

GP currently employs over 150 skilled professionals at its plant in Tacoma, Washington state, on the west coast of the USA. It produces high-temperature and industry standard tooling boards, thermal insulating bearing blocks, flexible seals, nuclear containers and a variety of aerospace and military custom applications.

Today its focus is on solving problems for customers through unique products and chemical technology.

Foundry pattern; certain of the GP foams can withstand high temperatures up to 200ºC and can, for example, be used in autoclaves

Kirk Lider (right) of General Plastics of the United States and the company’s new SA agent, Graham Blyth of Aerontec, with samples of some of GP’s wide range of foams. Blyth saw examples of components made with the American manufacturer’s specialised foams and realized these filled a need in the local market, leading to Aerontec’s appointment as local agent

www.aerontec.co.za www.generalplastics.com

USA’s new composite jet fighter A prototype of the United States’ new jet fighter, the F/A-37, underwent catapult fit checks for aircraft carrier launch recently. Officially known as the ‘Air Vehicle Number 1,’ the plane makes extensive use of high-tech composite solutions to reduce weight and improve performance. Although specs are classified, the super-cruise stealth fighter/bomber/interceptor is believed to be Mach 3.5 (top speed in the Mach 4 range) capable with a range of approximately 4000 nautical miles (about 7400kms)

26

AUGUST / SEPTEMBER 2012

Extraordinary Colours

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We have the latest computerised colour matching facilities and 21 years expertise.

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ASSOCIATION NEWS

Rotation 2012 in September ARMSA’S annual rotational moulding conference, Rotation 2012, takes place at the Zebula Golf Estate & Spa near Bela Bela in the Waterberg from 7-9 September.

ARMSA has been in existence since 1992 and its Rotation conferences have been held virtually annually since. The conference includes a ‘Product of the Year’ competition for roto moulding companies and a Student Design Competition, which Accelerate Design of Pretoria won the bronze awards in the Product of the Year has been held since 2000.

Winner! – The winner of last year’s ARMSA Product of the Year competition included CHM Plastics of Johannesburg with its cable runner board solution, a component used to run electrical cables across thoroughfares to protect against damage from passing vehicles or, in the case of pedestrian traffic, for the safety of humans or animals. An additional challenge was to mould the base of the component in a PVC plastisol, to give it flexibility. www.hickley.co.za

competition in 2011 for its roto moulded beehive. www.accelerate.co.za

www.zebula.co.za

Association of Rotational Moulders of Southern Africa Chairman Clive Robertson E-mail: cliverobertson@ iburst.co.za Tel: 082 880 4976

Secretary Anlé van Niekerk Tel: 082 782 0413 Fax: 012 666 8062 E-mail: anle@accelerate.co.za

www.armsa.co.za

ASSOCIATIONS AFFILIATED TO ARMSA THROUGH ARMO Association Francophone du Rotomoulage Associazione Italiana Stampaggio Rotazionale Association of Rotational Moulders Australasia Association of Rotational Moulding Central Europe Association of Rotomoulders Ireland The British Plastics Federation Rotational Moulders Group

State-of-art roto guide ROTATIONAL moulding is a very competitive alternative low-pressure, high-temperature manufacturing method to blow moulding, thermoforming and injection moulding for the manufacture of hollow plastic parts.

The book is authored by Prof Roy Crawford and Mark Kearns, who have been regular visitors and presenters at ARMSA’s Rotation conferences in Africa.

It offers designers the chance to produce relatively stress-free articles with uniform wall

Water saving shower – Neil Grantham of the University of Johannesburg won a Student Design award in 2010 for his ‘Eco Splash’ entry, a rainwater collection device which, when placed alongside a house, doubles up as a shower. The other benefit of the system is that the water drains into the garden

www.polymer-books.com

thickness and potentially complex shapes.

This second edition of the very popular ‘Practical Guide to Rotational Moulding’ describes the basic aspects of the process and the latest state-of-the-art developments in the industry.

It is completely revised and is extensively illustrated.

Besides those who work with roto moulding equipment, the guide will also be of interest to students of polymer processing.

It retails at €70.

The roto guide is a soft cover publication; a quick glance revealed that the authors, Crawford and Kearns, have confronted some complex roto challenges

Polystyrene recycling takes off in Zimbabwe with SA help THE Polystyrene Packaging Council (PSPC) has been invited by Versapak in Harare to assist with the setting up of a similar industry body to oversee the recycling of polystyrene in this neighbouring country.

According to PSPC director Adri Spangenberg, the Zimbabwean government and environmental organizations have begun putting pressure on local industry to address their polystyrene litter and recycling issues.

Apart from spelling out the importance of creating a sustainable and responsible polystyrene recycling forum and offering advice on the best investments to be made into infrastructure, the PSPC was also invited to offer advice on how to correct misconceptions that surround polystyrene and the importance of ongo28

AUGUST / SEPTEMBER 2012

ing consumer education.

A joint working group, represented by many of the Zimbabwean polystyrene industry’s role players, has already been established. A steering committee is driving the process forward and has taken on the responsibility of developing a strategic business plan that will be presented to the stakeholders.

“They have identified various objectives they would like to achieve during the short to medium term, such as investigating the pelletizing of polystyrene and the use of polystyrene in building projects. Zimbabwe is hoping to achieve PS recovery rate of 20% of total volume per annum and to set up a recycling programme first in Harare, followed by the rest of Zimbabwe.

However, they are kickstarting their shortterm activities by introducing the PSPC’s cooking bag project (in which recycled polystyrene is used for cooking bags) to

local communities, as well as the success we’ve achieved with the Breadtags for Wheelchairs project”, Adri added. www.polystyrenepackaging.co.za

Harare and chairPatience Nchenche of Versapak aging Council in Pack ne styre Poly new person of s director of ation oper irai, Dad Zimbabwe, Range berg, director of the Versapak and Adri Spangen ncil SA Polystyrene Packaging Cou

ASSOCIATION NEWS

Tangential mixer technology developments New HF rubber mixers achieve major output increase THE ability of rubber mixing specialist Farrel to achieve a major performance boost in its Banbury® compounding equipment was illustrated in a presentation

by Ian Latchem at an IOM³ function in Port Elizabeth in June.

ing Group’s impressive new technology centre in Freudenberg, Germany, where a range of equipment has been installed specifically for R+D both in house and as a facility for our customers to develop their products and process methods from laboratory stage through to automated production runs.

Latchem, who is based in the UK, worked in South Africa with Carst & Walker as a service engineer in the 1980s, servicing Farrel equipment and later as a product manager representing numerous rubber related manufacturers.

He subsequently returned to the UK and joined Farrel, inventor of the Banbury® mixer. Farrel has since become part of Harburg-Freudenberger Mixing Group (HF Mixing Group), which was formed following the merger of some of the top mixing equipment companies in the West, including Farrel, Harburg-Freudenberger and Pomini.

Carst & Walker is the SA agent for HF Mixing Group, which is the second largest mixing equipment manufacturer in the world, after Kobe of Japan. It has developed a reputation for focusing on continued R&D partnering with major rubber producers.

Ian’s presentation was effectively a report on the technology progress made in the last few years – and significant advances have been made. Most of the research work is conducted at HF Mix-

Even-speed rotors New developments include even-speed NST rotors: four wings on the rotors are specifically designed each with a specific function to optimise distribution and dispersion, eliminating the need for the oldfashioned 2-wing friction ratio rotors. The development also improves batch to batch repeatability and speeds up mixing, temperature control has been improved with force tip cooling that improves efficiency in silica/silane compounding by drastically reducing heat buildup.

The end frame has been redesigned, vastly improving access to dust rings. Dust seals now have three cylinders per seal giving an equal pressure distribution over the seal face for improved performance, the drop door is now wider, which allows for faster discharge, enhanced cooling and virtually eliminates material hang-up.

Hydraulic hoppers are standard being accurate and reproducible. Intelligent ram control – variable ram speed and position controller eliminates need for a ram sweep, thus saving time and energy.

New IOM³ national committee Craig, in what is now an appointed role.

Since Richard Blyth left the position about two years ago, the secretarial functions became part-time jobs of NEC members, so it’s hoped this will assist in improving the service to IOM³ members.

André takes over as chairman from Hans Strydom, who did an excellent job during his tenure – in spite of the challenge of opening his own business, Rubber Nano Products, during the period.

ANDRÉ Cornelius of Orchem Trading is the new chairman of the Institute of Materials in South Africa.

The new IOM³ national executive committee comprises Jaco Smith as vice-chairman (also KZN chairman); Coen Burger (Eastern Cape chairman); Spike Taylor (Northern branch chairman) and Georg Cronje (also Northern branch), as treasurer.

The new secretary is Wendy Knott-

Institute of Materials: Southern Africa Region

30

National Chairman André Cornelius p. 071 682 9885 andrec@orchemtrading.co.za

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

Vice-chair/KwaZulu-Natal Jaco Smith c. 082 808 4703 jaco.smith@carst.co.za

Secretary Wendy Knott-Craig p. 073 201 8699 wknottcraig@vodamail.co.za

AUGUST / SEPTEMBER 2012

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

www.iom3.co.za

www.iom3.org

The speaker, Ian Latchem (right) of HF Mixing Group, following the presentation in Port Elizabeth with IOM³ Eastern Cape chairman Coen Burger and Dr Kathy Garde of Carst & Walker, who hosted the function

The bottom weight has been changed from V bottom to keel-shaped, assisting in distributive movement of material, which also has the result of improving repeatability and predictability in compounds.

The new ram unit also reduces noise. New crack-free and corrosion-resistant hard facing extends lifespan particularly when processing silica reinforced compounds.

The final result of all this activity is an increase in productivity and a reduction in compounding cost.

• THANKS TO CARST & WALKER FOR SPONSORING THE FUNCTION (C & W IS THE SA AGENT FOR FARREL, HF MIXING GROUP). www.farrel.com

‘French letters and flat tyres’ at Foundation Lecture in October THE IOM³ Foundation Lecture for 2012 is to be delivered by Dr Chris Woolard, of the Sasol Advanced Fuels Laboratory at UCT, at Emperor’s Palace in Johannesburg on Thursday, 11 October.

The title of his presentation is ‘French Letters, Flat Tyres and Fuel-Rubber Barrier Materials: Research and Application’.

Chris is leader of the Sasol Advanced Fuels Laboratory at the University of Cape Town and principal scientist for Sasol Technology.

The dress code for this main event of the IOM³ calendar is formal or lounge suit.

For more information, contact Wendy Knott-Craig on wknottcraig@vodamail.co.za or 073 201 8699.

ASB-50MB

More than one step ahead

ASB-70DPH / ASB-70DPW

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

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

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

PF6-2B / PF8-4B

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

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

Small and medium bottle production PF6-2B / PF8-4B Capable of moulding containers up to 1.5L (PF84B) and 3L (PF6-2B). Optional neck orientation or preferential heating systems expands the capabilities for extreme oval designs. The PF8-4B is ideally suited to 500ml water or sports drinks containers, while the PF6-2B is ideal for containers in the 1.5L to 3L range.

Preform production for small and medium bottle PM-70/65NII / PM-70/111N Ideally matched to the CM and HSB machines for production of hot fillable PET bottles. Also suited to any general moulding operation for a range of performs from 0.3L up to 5L, neck sizes up to 48mm (thread diameter) and from 8 to 24 cavities.

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

ASSOCIATION NEWS

Simplify your business, and remember to have fun!

Observations of business in California and cruise on carrier

Steve Mountain (right), the speaker at the Western Cape AGM, with Dudley Flugel of Nedbank, sponsor of the evening, and branch chairman Billy Macmillan

KEEP your business simple, and remember to leave time for fun!

That was the unexpected (but important) message from Steve Mountain in his address at the AGM of the PISA Western Cape branch on 26 June.

Formerly MD of Plastamid, the material supply business, Steve had taken ‘early retirement’ some years ago and set up a consultancy business, covering mainly the chemical and manufacturing industries.

That’s also given him the opportunity to observe business strategies from a dis-

tance, something which he has long been interested in.

He was able to take the process international during a recent three-month visit to California in the USA, where he made ad hoc observations of American business strategies. In Steve’s view, the Americans have got a positive attitude towards running businesses. A lot of middle-aged businessmen as well as start-up businesses have had to come up with novel strategies since the financial downturn of 2008. Stationing a few machines adjacent to retail outlets to make packaging containers on demand is, for example, now considered a very viable solution in the state. And many small businesses are now active in the wind and solar energy sector, with photovoltaic solutions being the preferred choice. California, incidentally, has a similar climate to that of South Africa, with a lot of sun and wind!

Californians appear to approach training with enthusiasm and possibly even more enthusiasm towards applying those skills actively, says Steve. A business-minded culture prevails: in fact, it’s generally expected that young people in California will start businesses … and if it fails, the ethos is to put that behind you and start again!

The American system, says Steve, makes it easier to get started. But the opposite side of the coin is that it’s also easier to get fired. By that he means that “accountability” is a recognised aspect of industry in the USA: meaning that if you don’t measure up you’re probably going to get the chop! But, rather than dwell on the losses, the culture suggests it’s preferable to avoid the labour legislation route, get into business and, just as importantly, make sure you’re having fun.

With that aspect in mind, Steve also managed to get a berth on the USS Carl Vinson, a nuclear-powered aircraft carrier in the United States Navy’s 5th Fleet, on a cruise from Hawaii back to San Diego on the US west coast. Besides enabling Steve to tick one more item off his ‘bucket list’, this gave him the opportunity to view the Americans’ awesome firepower.

• SHOULD READERS WANT MORE INFORMATION ABOUT THE PRESENTATION AND EXPERIENCE, STEPHEN CAN BE CONTACTED AT stephen@ladibird.co.za OR 083 255 7068.

• THANK YOU TO NEDBANK FOR SPONSORING THE FUNCTION.

The pride Americans take in their armed forces is possibly difficult for people in South Africa to comprehend, but the scale of armaments isn’t. The USS Carl Vinson aircraft carrier, which Steve Mountain joined for a 5-day cruise in the Pacific, has a staff complement of over 5000 and carries over 70 warplanes … plus its accompanying fleet includes a nuclear-powered submarine (which leads the sailing formation) as well as a number of destroyer and attack craft. Steve was able to witness the simultaneous launching of planes (where a plastic coupling on the catapult drew his interest, but which he wasn’t able to learn anything of); a sound barrier-breaking flyby; the tense moments of return landing … and was also roped in for firefighting drill.

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Cape toolmaking training programme shows results THERE’S good news emanating from the 63 students now in their second and third Western Cape Tooling Initiative (WCTI), years, which is a good indicator of the sucwhich is one of the Regional Tooling cess of this skills development initiative.

Initiatives (RTI) involved in the training of toolmaking apprentices around the country.

Fightback Together with the National Tooling The tooling industry in South Africa has Initiative (NTI), the WCTI has succeeded been subjected to intense pressure for an in drawing a full complement of students extended period, dating back to even the to participate in the pilot Tool, Die and 1980s, leading to the recent critical shortMouldmaking Toolmaking Apprenticeship age of skilled and qualified toolmakers, Programme being conducted at Northlink engineers, designers and artisans. The lack FET College at Wingfield in Cape Town. of capacity development has been worst felt The WCTI, which has offices at Northlink in the automotive sector, where the number FET College, is presently engaged with of toolmakers employed in South Africa has the third year of the 4-year apprenticeship fallen by as much as 80% since 1990. programme, with the first students expected TASA, working together with the TDM to qualify as Toolmakers at the end of 2013.

(Tool, Die and Mouldmaking) sector, has Since the shortage of toolmakers for the succeeded in slowly turning this situation plastics as well as toolmaking sectors was around. TASA initially succeeded in obtainhighlighted a number of years ago, compaing funding from government, which allowed nies have feared that for the capacity Several of Western the situation would expansion (particularly not improve. These of facilities for training Cape’s top toolmakers suspicions were laid to such as at the WCTI), present at function rest, however, by John and now we’ve seen McEwan, CEO of the WCTI at a joint PISA/ the progress made at a centre such as the TASA (Toolmaking Association of South WCTI. Africa) function held at the college in June.

Possibly the most notable aspect of McEwan, along with a group of the lectur- the process has been the involvement of ers, outlined the details of the Apprenticetoolmaking companies. These businesses ship programme as well as the progress have been employing trainees on an inmade at the Northlink FET College which service basis (between training modules), can boast expansive facilities along with a virtually as the original apprenticeship wide range of well-maintained equipment on system used to work. This has given these which students can undergo technical trainyoung individuals the opportunity to gain ing. There has been a relatively low dropout practical experience and see a future for rate of 16% from the programme so far, with themselves in the industry.

FOCUS ON KZN T ECONOMIC DEVELOPMEN THE 40th annual general meeting of the PISA KZN branch was held on 12 June, and it was appropriate that the focus was on the development of Durban and the KZN province as a whole as the speaker was Andrew Layman, CEO of the Durban Chamber of Commerce.

With a Master of Commerce degree specialising in local economic development, Andrew writes columns for the ‘Natal Mercury’ and the ‘Witness’ newspapers. He was principal of Alexander Boys School in Pietermaritzburg prior to joining the Durban Chamber. Andrew’s predictions for KZN for the near future are that the province’s economy will grow and be of interest for business investors, especially if the proposed dugout harbour for container ships goes ahead as planned.

PHOTO: JOHN MARTIN

Andrew Layman, CEO of the Durban Chamber of Commerce, received a gift from KZN branch chairman Garth Taylor following his presentation at the Westville Country Club on 12 June

1

• THE WCTI IS A SECTION 21 (NOT FOR PROFIT) COMPANY FORMED THROUGH A PARTNERSHIP BETWEEN TASA AND THE WESTERN CAPE GOVERNMENT. SIMILAR INSTITUTIONS EXIST IN THE OTHER PROVINCES, OPERATING IN CONJUNCTION WITH LOCAL GOVERNMENT. www.ntipweb.co.za

John McEwan, CEO of the WCTI (second from right), who hosted the TASA/PISA event, with (from the left) Marthinus van Wyk of the Western Cape government; Alan de Cerff of Expertool, who is also chairman of the WCTI; Billy MacMillan, chairman of PISA Western Cape; and Richard Carter of PISA/TASA

A tour of both the impressive training facility and Northlink College at Wingfield was conducted after the talk; over 12,000 students are enrolled at the college, where a wide range of training is conducted

2

PISA KZN golf day 2012

PHOTOS: JOHN MARTIN

PISA KZN’s annual golf day was once again a resounding success, with Team GVR coming out tops and Designa following close behind.

1. Proving their prowess on the golf course were the GVR team, Gordon Manning, Vernon Raath (sponsor), Gary Raath, Les McClurg and Garth Taylor 2. Second-placed team were from Designa, Ryan Sutherland, Brett Aitken, Justin de Neef and Christian Matthews

Don’t forget PISA Northerns’ golf day!

PISA Northern branch will host a Golf Day on 21 September at Blue Valley Golf and Country Club, Midrand. Members will be provided with more info nearer the time. If you have any queries, contact Lowrie Sharp, tel: 011 793 4691 or lowrieplasticsmedia@absamail.co.za AUGUST / SEPTEMBER 2012

33

ASSOCIATION NEWS

Next wave for change Ocean and water health under the spotlight on World Ocean Day

The clean up group from Hosaf Fibres, surrounding schools and the community

PLASTICS|SA encouraged South Africa’s youth to recognise their importance in the global 2012 theme Youth: the Next Wave for Change on 8 June, World Oceans Day. “As one of the signatories to the Plastics Industries’ Global Declaration on Marine Litter, Plastics|SA is involved in this exciting campaign which seeks to find solutions to the growing problem. We are purposely including our nation’s youth as we pave the way for generations to come”, said Anton Hanekom, executive director of Plastics|SA. Plastics industry representatives from across the world met in Dubai in November last year to create a global action plan for solutions on marine litter. 56 Plastics industry organisations around the world adopted the “Declaration for Solutions on Marine Litter” which also identified about 100 projects to be carried out in 32 countries, including South Africa.

Plastics|SA annually coordinates volunteer initiatives such as South Africa’s participation in the International Coastal Clean-Up Day. Plastics|SA embarked on two new

initiatives during World Environment Week to raise public awareness of ocean health: World Ocean Day celebration on 8 June 2012 and Beach Clean Up on 10 June.

Ezemvelo KZN Wildlife and Plastics|SA hosted a World Oceans Day celebration at the Ezemvelo KZN Wildlife Beachwood Mangroves in Durban on 8 June. The day showcased the results of the ‘Mayday for Rivers’, an epic walk down the entire length of the uMngeni River, from source to sea, which started on 1 May by members from DUCT (Duzi-uMngeni Conservation Trust).

Various schools from the area, organisations and members of the plastics industry took part in the day’s events and were inspired by the 12 year old Plastics|SA youth ambassador and ‘Aqua Angel’, Nikita van der Merwe, who recently embarked on rowing on rivers and dams around KZN in her kayak to raise awareness of water pollution. www.plasticsinfo.co.za

Douw Steyn (Director Sustainability: Plastics|SA) and Belinda Booker (Petco) with Wayne Munger (Ezemvelo KZN Wildlife) in front of one of the kayaks donated by Plastics|SA to Ezemvelo KZN Wildlife’s honorary rangers.

The rangers make full use of the kayak in their regular cleaning and monitoring of the Umgeni River mouth and Beachwood Mangroves

Nikita van der Merwe (Aqua Angel and youth ambassador for Plastics|SA Cleanup and Reycle 2012) with other young friends cleaning the mangroves

Deaf students offered bursaries for training in composites PLASTICS|SA, together with training partners Whisper Boat Building Academy (WBBA) and the Marine Industry Association of South Africa are inviting deaf students to apply for merSETA funded bursaries that will allow them to train in the art of working with composites during the period 13 August – 14 December 2012.

According to Jo Fitzell, regional training manager for Plastics|SA in the Western Cape, this will be the third intake of students who are deaf or hard of hearing. “The deaf 34

AUGUST / SEPTEMBER 2012

students who graduate from this course offer a sought after skill that allows them to work in a variety of fields in the plastics industry, ranging from working as laminators for boat builders, to swimming pool constructors, canopy constructors and other composite fields”, Fitzell says.

The Whisper Boat Building Academy was founded by Peter Jacops in 2004 as a nonprofit organization to teach deaf students from the townships the art of boat building.

Training takes place with the help of a full-

time sign language interpreter and consists of class-room based theoretical training at the Plastics|SA offices in Maitland, combined with practical workplace experience, presented as individual skills programmes, offered at the new Whisper Boatbuilding facilities in Epping Industrial.

• FOR MORE INFORMATION, PLEASE SMS 072 8363998 OR CALL 021 591 5512, OR VISIT WWW.PLASTICSINFO.CO.ZA

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

ASSOCIATION NEWS

IFPA uses identification stamps to ensure quality installations Welder Identification System allows for a welder to be traced back to every weld he has ever done

A welder applies his unique IFPA identification stamp after completing a weld

IN A MOVE to ensure consistent high quality of welding and introduce transparency and accountability in the industry, the Installation and Fabrication Plastics Pipe Association (IFPA) has issued all of its welders with identification stamps.

According to IFPA Chairman, Mike Smart, its welders were required to be recertificated before they were issued with their unique stamps.

“The annual recertification of welders was instituted by the Plastics Federation (now Plastics|SA) in 2000 in an effort to better ensure quality of practical work. However, in September 2010 it has been decided that IFPA members would have the benefit of only having to recertify their welders once in a three year renewal cycle, while A closer look at non-IFPA members the IFPA would be required to cerwelder tify their welders annually”, identificasays Smart. tion stamp As part of IFPA’s mandate and mission to ensure that its members adhere to the Association’s objectives of ensuring consistently high standards of plastic pipe fabrication and installation, they felt it necessary to also develop a mechanism whereby a welder could be traced back to every weld he has ever done. A Welder Identification System was implemented by Plastics|SA and IFPA in 2010.

stabilizers that are non-toxic to humans.

Calcium/zinc stabilizers have been used in PVC applications for more than 25 years and, in addition to being non-toxic, they are essential elements to the human body. Organic-based stabilizers are predominantly based on uracyl technology and are heavy metal and odour free, and approved for potable water and food contact applications.

Heavy metal free!

SA pipe industry 100% lead-free LEAD has been eliminated from all locallymanufactured plastic pipe products and all plastic pipes manufactured by the Southern African Plastic Pipe Manufacturers Association (SAPPMA) are guaranteed to be free of heavy metals.

“We embarked on this journey in 2006, as a voluntary policy of heavy metal free stabilizers for the manufacture of PVC pipes. The reason for the initiative was based on health and environmental considerations and we are immensely proud of having reached our goal of eliminating all lead stabilizers from SAPPMA members’ piping products five years ahead of the anticipated European Union (EU) targets”, said Jan Venter, CEO of SAPPMA. As a member of the Southern African 36

AUGUST / SEPTEMBER 2012

“Since then, every IFPA welder has been issued with a unique number, printed on an identification card, along with his photograph. Each IFPA Member Company is expected to compliment the system of traceability with the use of a stamp on each weld, displaying the IFPA company number, the unique welder number and the IFPA logo”, Smart explains. The stamp is made of special hardened steel and can be used next to a weld if the weld surface is too small.

Members are tasked with the responsibility of ensuring the stamps made for their welders are kept up to date; to verify the specific discipline that the welder has been qualified for and control employee activities such as moonlighting. These are not the responsibility of IFPA. Concludes Jan Venter, CEO of SAPPMA: “IFPA is an initiative of SAPPMA and was formed with the view to expand regulation of the Plastic Pipe Industry in Southern Africa. We fully support and endorse this programme that proves our commitment to go further on the quality value chain. This move has also been welcomed and applauded by customers who appreciate the level of transparency and accountability we try to introduce and maintain in this highly specialised industry”.

www.sappma.co.za

Vinyls Association (SAVA), SAPPMA was also one of the signatories of the Association’s Product Stewardship Programme – a voluntary programme aimed at ensuring that all heavy metal additives (primarily lead) are removed from their workplace environments.

SAPPMA members have replaced lead with calcium/zinc and organic-based

Southern African Plastic Pipe Manufacturers Association (SAPPMA) Director Jan Venter p. 012 548 0149 c. 079 506 0484 e. janventer@3gi.co.za

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

www.sappma.co.za

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ASSOCIATION NEWS

BADAMID ® PA6, PA6.6, PA6.6/6

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‘Pipe VI’ conference in September

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SAPPMA’S 6th annual conference will take place on 18 September at the Bytes Conference Centre in Midrand.

This year’s Pipe VI Conference will focus on the importance of pipes in water distribution and will attempt to help design engineers and specifiers to make an informed decision when selecting material and products.

Dr Anthony Turton, an independent Dr Anthony Turton consultant and previously associated with the CSIR and the University of the Orange Free State, has been invited as keynote speaker.

Individuals interested in presenting papers at the conference are invited to submit their particulars and abstracts to Louise Muller at admin@Sappma.co.za before 30 June. Early bird offer to delegates: R750.00 for SAPPMA members and R1500.00 for non-members for all bookings before 31 July.

More information and electronic registration forms available on the SAPPMA website:

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3rd Revision of SAPPMA technical manual now available THE Southern African Plastic Pipe Manufacturer’s Association (SAPPMA) has published and released a third revision of its Technical Manual, aimed at assisting engineers who are involved in the plastic pipe industry to make informed decisions.

“The purpose of this manual is to provide basic, relevant information and the guidance needed to ensure that plastic pipes for water supply and waste-water disposal applications are correctly specified and selected”, explained SAPPMA chief executive officer, Jan Venter.

Although this manual does not attempt to replace published text books and codes on the subject, Venter said that it is a basic guide to the use, selection and specification of these products. It covers the differences between the various types of plastic pipes and the basic procedures for determining product size, strength and material properties for a range of applications.

The latest revision also includes sections on hot and cold water plumbing pipes, HDPE fabricated fittings as well as the jointing of HDPE. For a limited period copies of the publication have been made available to design and civil engineers free of charge via SAICE and as a service to the industry.

“Poor quality plastic pipe is not necessarily obvious from a visual point of view, which makes it even more important for design engineers or specifiers to apply all available precautions in the selection of manufacturers, suppliers and installers”, Venter said, adding that pipe manufacturers and installers who are members of SAPPMA and IFPA are subjected to additional quality control measures over and above the national standards.

• THE TECHNICAL MANUAL COSTS R150 AND CAN BE BOUGHT BY CONTACTING LOUISE MULLER ON ADMIN@SAPPMA.CO.ZA

AUGUST / SEPTEMBER 2012 39

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INDUSTRY NEWS

SA PLASTIC STAMP S O APPROV F AL

Plastic pelagic www.uncsd2012.org

Gigantic glowing fish sculptures made from recycled PET bottles are making Rio de Janiero’s beaches even more of an attraction than they usually are!

The scales of the epic sculptures are made by lining up hundreds of empty clear plastic bottles, giving the fish a shimmer day and night. The glowing installations appear on the popular Botafogo Beach as part of the Rio +20 conference. The sculpture, created for the UN Conference of Sustainable Development (Rio +20), brings awareness to both the importance of recycling, and its relationship to marine life.

Gravimetric drying hopper offers energy reduction & control Capable of tracking filling and discharge via ‘gain in weight’ and ‘loss in weight’ principles in most energy efficient way available tion for each drying hopper. This ramps THE Gravi-Dryer technology is a new the airflow up and down according to the range of energy efficient materials hanactual material consumption. Furtherdling equipment from machinery group more the filling of a drying hopper via the Labotek. The technology has been under ‘ramp-up’ principle eliminates the risk of development since 2007 and recently over-drying the raw came to the market The system is based on the materials. as a successful result Labo-Net field bus control When material of close partnerships usage is lowered, with several plastic technology, combined with the central desiccant processors. load cell systems and air flow dryer will perform The system is regulation on each drying automatic adjustbased on the Labohopper connected. ment of dry air flow Net field bus control through the built-in frequency control. technology, combined with load cell The Gravi-Dryer then stores processed systems and air flow regulation on each data for corporate material throughput drying hopper connected. A gravimetric drying hopper is capable of tracking the fill- management. The online consumption of each material type is stored and is easily ing and discharge of plastic raw materials retrieved through the inbuilt hard drive. via the ‘gain in weight’ and ‘loss in weight’ The current load of each drying hopper is principles, in the most energy efficient way shown on-screen and gives the operator available. the possibility to connect either more or The Gravi-Dryer has accuracy of +/less process equipment as required.

0.5% and enables full control and tracking The filling of each Gravi-Dryer is fully history of the individual material consump40

AUGUST / SEPTEMBER 2012

automated and adjusted according to material usage without any manual interference. The Labo-Net control has automated self-learning logic and monitors any variation to the material usage, correcting parameters accordingly if required.

In addition to developing new technology Labotek also serve the industry with systems and solutions in storing, conveying, drying, dosing and mixing, gravimetric blending, central feeding, and crystalizing.

Labotek A/S was founded in 1943 and is 100% Danish-owned, with its headquarters in Frederikssund, Denmark. Today, Labotek is one of Europe’s leading producers of ancillary equipment and centralized systems for the plastics industry.

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TECHNICAL

Unique laser system can build

3D objects out of metal powder ‘Selective melting and micro-welding by laser’ at Stellenbosch University A STATE-OF-THE-ART laser machine Engineering. capable of building complex three dimenThe IAT is an initiative of the Department sional objects out of fine metal powder – of Science and Technology, implemented microscopic layer by layer – was unveiled through the TIA. It has branches at Stelat Stellenbosch lenbosch University, University in May. Tshwane University of Primary application is Known as the M2 Technology and the production of complex LaserCusing System, Walter Sisulu Univertooling inserts for moulds the machine has sity. The TIA goal is to been imported from stimulate technological Germany at a cost of R5-million, funded by innovation in South Africa. the Technology Innovation Agency (TIA).

The M2 LaserCusing System’s primary The only one of its kind in the country, the application is the production of complex system has been installed at the Institute of tooling inserts for metal moulds used in Advanced Tooling (IAT), hosted within the various industries. Moulds are routinely Rapid Product Development Laboratory employed to manufacture products made in the university’s Department of Industrial from a variety of substances, such as

plastic, glass and metal. In addition, the machine can also be used to manufacture advanced metal components for utilisation in the aerospace, automotive, medical and dental industries. This wide range of applications facilitates synergies between numerous research, development and industrial projects.

“This machine can produce components that cannot be made in any other way. It allows for complete design freedom. Whatever can be imagined, can be built with this system,” said Professor Dimitri Dimitrov, head of the Rapid Product Development Laboratory at Stellenbosch. He also acts as mentor at the IAT. One of the machine’s major advantages

Complex parts with extremely fine detail and tolerances are achievable. These parts were produced during the commissioning of the machine. The part on the right is about 30x30mm and 40mm high. The small gaps are 1mm to 2mm and even less in some places. None of the parts are bigger than 60mmx60mm.

However, the build possible on the machine is 250x250x280mm 42 AUGUST / SEPTEMBER 2012

Inserts for this mould, produced on the system, would have been extremely difficult to produce with existing technology; the mould is being used to produce a cutlery drainer rack

is that it can process a wide variety of metals, such as aluminium, stainless steel, various hot-work tooling steels, titanium, cobalt-chrome and nickel-based alloys.

Dimitrov pointed out that although the machine can build 3D metal objects, it should not be confused with 3D printing.

“This system also uses an additive process, but it is not the same as 3D printing.

In printing, a substance is laid down layer by layer, and an object is built up by using binder liquid jetted by a printing head. With this machine, metal powder is fused by laser. It is basically selective melting and micro-welding by laser.”

The system was developed and made

by Hoffman Innovation Group AG, a leading German tooling producer. The term LaserCusing is made up of the letter ‘C’ from ‘concept laser’ and the word ‘Fusing’ for ‘complete melting’. The manufacturers describe the system as ‘the technology of the future’.

The metal powder used in the system

The M2 LaserCusing System can produce complex structures by fusing very fine metal powders at high temperatures of about 1000ºC

consists of extremely fine granules of 20-40 microns each. The laser fuses them at temperatures of above 1000°C. And it does so in very thin layers of 20-30 microns each.

The system will be used for advanced research purposes by post-graduate students at SU and IAT tooling engineers. In addition, the system will service the tooling industry, which will help create employment opportunities and stimulate economic growth. The system can provide a productivity improvement for various moulding and casting processes of about 30% through cycle time reduction.

“The SSME sector now has access to an advanced manufacturing capability for the production of complex tooling inserts and other objects. Before, they would have had to go overseas; now they can do it right here. Local industry has already shown

significant interest in this advanced technology,” said Dimitrov.

The funding application to the TIA was supported by the Tooling Association of South Africa (TASA), which recommended the equipment to support the industry through cutting edge technologies.

The advantages that the system brings to the industry and research community alike are in line with the objectives of Stellenbosch University’s HOPE Project, which uses the institution’s academic and research excellence to tackle developmental challenges in society.

• INQUIRIES: MIKE SAXER, MIKESAXER@SUN.AC.ZA www.sun.ac.za AUGUST / SEPTEMBER 2012 43

MORE THAN JUST PE & PP

PRODUCED IN MIDDLE EAST

The most visible use of PET in the Middle East is packaging: water, fruit juice and carbonated soft drink bottles, thermoformed trays, barrier films and blister packs

Largest non-polyolefin polymers produced is PET three plants produce more than 2 million tons a year

BY DR NIALL MARSHALL

FEATURE

WHEN the polymer industry was started in the Middle East in the 1980’s it was to take advantage of the readily available feedstocks that were a by-product of oil production, namely ethylene.

Today polyethylene and polypropylene account for almost 90% of the plastic produced in the Middle East.

However, the slate of new feedstocks that are becoming available from the new petrochemical complexes are diversifying the range of polymers produced in the region. And even if only 10% of the millions of tons of polymer produced annually are not polyolefins, it is still a lot of polymer!

By far the largest of the non-polyolefin polymers produced is PET (polyethylene terephthalate). Just three plants (in Oman, Saudi Arabia and U.A.E.) produce more than 2 million tons per year and planned expansions and debottlenecking will increase that total further by 2013. There is also a 420 000 tpa plant scheduled for start-up at the end of 2012 in Egypt and plans for another 800 000 tpa plant in Saudi Arabia was announced last year.

The most visible use of PET is packaging: water, fruit juice and carbonated soft drink bottles, thermoformed trays, barrier films and blister packs. Not surprisingly these are also the main uses in the Middle East. But PET, when it’s not ‘PET’, is ‘polyester’ made into fibres. Some of the polyester is used in the region to make carpets, textiles, nonwoven fabrics and tyre cords although polymer chips are also exported.

44 AUGUST / SEPTEMBER 2012

But, unlike most other polymer produced in the Middle East and exported, not all the PET that is exported from the region is exported as a raw material – PET and APET sheet for packaging is exported globally. In fact Octal Petrochemicals in Oman is the largest producer of PET clear rigid sheet in the world.

Surprisingly PVC is not produced in large quantities - only about 500 000 tpa in Saudi Arabia and Egypt, although both emulsionand suspension-PVC is produced. Most of the PVC used in pipes, membranes, wire and cables is imported into the region although vinyl chloride monomer (used to make PVC) is produced in Qatar and exported to Asia.

Polystyrene is produced in Saudi Arabia and there is also a plant under construction in Egypt. The polystyrene (GPPS, HIPS and EPS) is used mostly to make thermoformed and injection moulded packaging and houseware in the region. Another styrenic polymer, ABS, will also be produced in Saudi Arabia from 2014 on a new 200 000 tpa plant.

Another family of polymers due to be produced in Saudi Arabia in the near future are elastomers and synthetic rubbers. In 2015 a 400 000 tpa plant comes on-line producing a range of butadiene rubbers (used in tyres and gaskets) and EPDM (used in seals, membranes and automotive applications).

With the acquisition of GE Plastics in 2007, SABIC became one of the major world producers of engineering polymers with a range that included ABS, polycarbonate, acetal (POM) and polyamide. Prior to the purchase of these manufacturing assets SABIC didn’t produce any of these polymers although a polycarbonate plant, which has since started production, was planned for Saudi Arabia. Polycarbonate is used in

applications as diverse as electronic components, light housings and skylights, all of which are manufactured in the Middle East.

Polycarbonate is also used in optical media – CDs, DVDs and Blu-ray discs - which is a small application in the region and grades for these uses are exported from the area.

Not all the planned new polymer plants are the mega-scale plants usually associated with the region. SABIC has announced plans to produce acrylic (PMMA) for the construction, appliance and medical device market on a new 50 000 tpa plant. PMMA is also used in skylights, signs and glazing and is used extensively in the region and so it is expected that a significant portion of the new plant’s production will be used in the Middle East.

Another polymer that SABIC is due to debut Saudi production in 2013 is acetal (POM) which is widely used in moving parts where its dimension stability and wear resistance are valued. As for polyamide: the Chevron Phillips joint venture in Saudi Arabia has announced plans to produce PA 6,6 and SABIC has also expressed their interest in building capacity in Saudi Arabia – but for now the ‘nylon bag’ at the supermarket is still polyethylene!

NIALL CAN BE REACHED AT: NIALL.MARSHALL@EVERSPRINGME.COM

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

ON THE MOVE ship building with Zanogen’s customers and also on improving overall customer service.

Rob Harris has moved to Botswana, where he has joined Chloride Exide Botswana. He was formerly at Pi Shurlock in Port Elizabeth, one of SA’s top battery manufacturing businesses.

Jacques Lightfoot has been appointed sustainability manager at Plastics|SA. Jacques’s career in the plastics industry began in 2000 when he started working in the family business, Light Enterprises (now called RNL Plastics). For the past ďŹ ve and a half years, Jacques has been the technical training ofďŹ cer at Plastics|SA.

Erica de Jager has joined Zanogen Machine Knives.

Erica’s main area of focus is customer relations management. Erica will be focusing on relation-

Plastics|SA has made three new appointments at its head ofďŹ ce in Midrand, Johannesburg: Dianne Blumberg has been appointed online editor at Plastics|SA. Although Dianne has managed to juggle her duties as PA to the executive director with those of updating and maintaining Plastics|SA’s websites, the recent launch of its new online and social media campaigns has necessitated the need for a full-time online editor.

Amos Velaphi Mkhonto has been appointed as technical trainer at Plastics|SA. Amos completed his National Higher Diploma in Polymer Technology in 2000 before he kicked off his career in the plastics industry as a setter at Megapak in Olifantsfontein.

Before joining Plastics|SA, Amos worked for Polyoak Packaging in Germiston.

Keith Reading has been appointed technical sales and services director at Mouldplas Marketing, in charge of the Wittmann Battenfeld section of the business. Keith started his plastics career with GF Plastics 15 years ago before moving on to Hestico where he gained invaluable technical experience on Arburg and Wittmann machinery, as well as Uniloy blow moulding machines, assisting with some of the industry’s largest installations and rebuilds to date. Keith moved on to PMS Plastics with Phillip Maye where his technical know-how was strengthened even further. Concorde Plastics was next on Keith’s journey where as technical manager he learned more about IML and became familiar with the medical and tooling sectors.

AUGUST / SEPTEMBER 2012 45

CPE

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PEOPLE

BASF Polyurethanes has appointed Christian Mirangels as the new managing director for South Africa. He takes over from Andrew Bailey, who has been appointed MD for business development at BASF West Africa, after 11 years with the SA business.

Mirangels has been with BASF Polyurethanes for over 17 years and has held senior positions in a number of successful entities, including BASF Polyurethanes Turkey, where he too was MD. He will focus on the overall operations of the South African systems house with a strong focus on business development within South and Sub-Saharan Africa of projects in selected industries.

yr

old research helps Stellenbosch chemists create

new separation technique

TRAINING

Process could make separation of xylene faster, more energy efficient CHEMISTS from Stellenbosch University namely ortho, meta, and para. Together with were inspired by 50 year old research ethylbenzene, they constitute the so-called to develop a new process to make the C8 aromatic compounds derived from crude separation of xylene, a chemical which is oil. These serve as the building blocks derived from crude oil, faster and more for the industrial scale synthesis of many energy efficient. It could benefit the producimportant chemical compounds needed to tion of pigments for the paint industry, produce polymers, resins, pigments, fungifungicides, polymers and various types of cides and motor fuel. plastics used today.

Prof Barbour explained why current Dr Matteo Lusi, who until recently was industrial methods are all very slow and ena postdoctoral fellow in the Department of ergy-intensive and require many separation Chemistry and Polymer Science carried steps. “It is currently extremely difficult and out the research, along with Prof Len expensive to separate these three isomers Barbour, South African Research Chair from one another, because they have such Initiative (SARChI) chair in Nanostructured similar physical properties, and even share Functional Materials at Stellenbosch almost the same boiling point,” he said.

University (SU).

They based their The work was rework on research Could benefit the cently published in the done more than 50 production of pigments top chemical journal years ago on how to for the paint industry, Angewandte Chemie, separate xylenes from and was also highthe liquid phase by fungicides, polymers and lighted in news articles using enclathration various types of plastics in Chemistry World, by octahedral metal used today. the news magazine of complexes. Clathrates the Royal Society of are intermediate beChemistry as well as Chemical and Engitween mixtures and true compounds. These neering News, published by the American porous compounds are formed when the Chemical Society. small molecules of one substance fill in the By using host-guest chemistry, they holes in the structural lattice of another solid are able to very selectively separate the substance, for instance the sulphur dioxide isomers of xylene as part of its purification molecules in ice crystals. process.

Back then, these so-called Werner Xylenes are benzene derivatives, with clathrates were deemed too costly as a three possible isomeric configurations, separation technique, because it involved 46

Prof Len Barbour

Dr Matheo Lusi

dissolving a host in the liquid and the forming crystals before the extraction of the product could take place. The technique has, however, since been used in chromatography to analyse mixtures of gases, liquids and dissolved substances.

Dr Lusi and Prof Barbour have now simplified this separation method by using a nickelbased metal complex as their host structure, and exposing the polycrystalline material to xylene vapour. It allows them to separate the three different xylene isomers much faster and more effectively, all in one process.

“This method seems promising to implement in industrial scale applications, such as pressure swing adsorption (PSA) processes that use a substrate with prioritized selectivity,” he explained.

Their findings have been patented, with the help of the University’s INNOVUS office.

“Now it’s up to the engineers to prove that it can be used in a large scale production process,” Prof Barbour added.

AUGUST / SEPTEMBER 2012

#/34 #/-0%4)4)6% /. ',/"!, 3#!,% s 0RESS TOOLS s #OMPONENT PRODUCTION SUPPLY s $EEP DRAWING TOOLS s 4HIN WALL HIGH PRECISION THROUGH HARDENED MOULDS s 3ILICONE MOULDS

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Polymer scientist celebrates PhD ‘quadruplets’ POLYMER scientist Prof Bert Klumperman had every reason to feel like a proud father at the recent graduation ceremony at Stellenbosch University when four doctoral students whose research he had supervised over the past few years all received their PhD degrees.

Dr Njabu Gule, Dr Rueben Pfukwa, Dr Nathalie Bailly and Dr Osama Bshena were all guided through their PhD years by Prof Klumperman, holder of a South African Research Chair (SARChI) on Advanced Macromolecular Architectures in the Department of Chemistry and Polymer Science.

Dr Bailly worked in the ďŹ eld of anti-tumour drug delivery. She developed a delivery vehicle consisting of an amphiphilic block copolymer. In vitro tests show very promising results in the uptake of the drug-loaded copolymer assemblies by tumour cells.

Dr Gule helped to develop the nanoďŹ bres used to develop the

DMP Training starts in KZN Moses Mnyakeni provides full training service for setters, operators A NEW training provider, DMP Training, has started in KZN – focussed speciďŹ cally on training for the plastics industry.

DMP is the progeny of Moses Mnyakeni, who has been involved in the industry since 1986. Moses spent the early part of his career as a trainer with the then Plastics Federation in Johannesburg, moved to Durban in the late 1990s as a trainer with the Federation in KZN and subsequently switched to the blow and injection moulding business.

Experience gained in the converting sector has honed his skills, but Moses realized recently it was “necessary to go with my heart

Dr Njabu Gule, Dr Rueben Pfukwa, Dr Nathalie Bailly and Dr Osama Bshena with their supervisor, Prof Bert Klumperman, holder of a South African Research Chair (SARChI) on Advanced Macromolecular Architectures in the Department of Chemistry and Polymer Science

Stellenbosch University Water Institute teabag water ďŹ lter.

Antimicrobial polymer nanoďŹ bre technology developed by Dr Bshena and Prof Klumperman could potentially be used in the air ďŹ lters of hospitals to curb the spread of bacteria.

Dr Pfukwa worked on the hierarchical self-assembly of novel para-aryltriazole helical foldamers.

and do what I love and enjoy the most, which is skills development�. “With the skills and experience I have developed over the years I believe I will be able to make a positive contribution to the skills development of employees within the SA plastics industry,� said Moses.

DMP provides • certiďŹ cate plastics manufacturing from NQF 2-4; • setter/operator courses for raw materials; • setter/operator courses for blow moulding, extrusion, injection moulding, rotational moulding; • thermoplastic welding.

Besides training at its centre, Moses also offers on-the-job training at manufacturing businesses.

Training in action – Moses Mnyakeni of DMP Training engages with students, helping to open career paths for aspirant trainees in KZN

DMP IS BASED AT WEARCHECK HOUSE, 16 SCHOOL ROAD, PINETOWN; PHONE 031 701 7628. www.dmptraining.co.za moses@dmptraining.co.za

AUGUST / SEPTEMBER 2012 47

%80%2)%.#% s &,%8)"),)49 s 30%%$ s !UTOMOTIVE MOULDS s -EDICAL COMPONENT MOULDS s YEARS EXPERIENCE s )3/ CERTIl ED TOOL ROOM s (OUSEWARE MOULDS s 0 % 4 PREFORM MOULDS BLOW MOULDS s )3/ CERTIl ED INJECTION MOULDING AND TESTING FACILITY s /PTIMISED FAST CYCLING MOULDS s #OST EFFECTIVE s 2APID PROTOTYPING AND #.# PROTOTYPE MANUFACTURE s &INITE ELEMENT STUDIES UNDERTAKEN

350%2 15!,) )/2 49

GETTING IT RIGHT

The Competition Act:

Relationships between parties on different levels of the supply chain

By Abena Danso, attorney in the Adams and Adams Competition Law Practice Group (abena@adamsadams.co.za)

LEGAL

Minimum resale price maintenance an absolute prohibition to the reseller that the recommendation is not binding on it and SECTION 5 of the Competition Act controls the relationship it will not face repercussions as a result of failing to sell at the between parties that operate on different levels of the supply recommended price. chain. This relationship is described as a ‘vertical relationship’ as The enforcement of MRPM can be achieved directly or indirectly. it is usually a top-down relationship e.g. an input supplier and a A supplier may, for example, restrict supply of a particular product manufacturer; manufacturer and wholesaler, etc. to a distributor if the distributor sells at prices below the prescribed Section 5 prohibits agreements between parties in a vertical price. The restriction of supply by the supplier is aimed at relationship if the agreement substantially prevents or lessens competition in a market, unless a party to the agreement can prove penalising the distributor for not selling at, or above, the prescribed price and is a contravention of section 5. A that there is a technological, efficiency or The reason commonly supplier would also be contravening the Act other pro-competitive gain resulting from that if it incentivises adherence by a distributor agreement that outweighs the effect. Unlike given by suppliers for to prescribed resale prices by, for example, section 4, which controls the relationship wanting to engage in resale offering additional discounts or rebates to between competitors and has a number of price maintenance relate distributors that sell at, or above, a prescribed absolute prohibitions, section 5 has only one to the protection of price. absolute prohibition - the practice of minimum The reason commonly given by suppliers resale price maintenance (MRPM). the product’s brand for wanting to engage in resale price MRPM refers to any practice by an value and image. maintenance relate to the protection of the upstream supplier to maintain or control the product’s brand value and image. Although brand protection is minimum price at which its product can be resold - in essence certainly a genuine goal, firms need to find other means to protect MRPM is vertical price fixing. A supplier who specifies the extent to the value of their brand. which a distributor may discount goods is also guilty of MRPM. Firms who contravene section 5 face the risk of either having an Where price lists are published by upstream suppliers to administrative penalty being imposed on it (which can be up to but downstream distributors, the price list must contain the words not exceed 10% of the firm’s annual turnover in South Africa and “recommended” to negate any inference to MRPM. An upstream its exports from South Africa in the preceding financial year), and/ supplier e.g. a manufacturer or input supplier may recommend or the firm may be required to unravel the agreement. a price at which its products may be on-sold, provided it is clear

www.adamsadams.co.za

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AUGUST / SEPTEMBER 2012

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

LEGAL

This relationship is described as a ‘vertical relationship’ as it is usually a top-down relationship e.g. an input supplier and a manufacturer; manufacturer and wholesaler, etc.

Firms, who take part in any of the following activities, may be at risk of falling foul of section 5: the firm has implemented measures which attempt to control the price at which products are resold by its distributors and or retailers; the firm publishes price lists and if its distributors do not adhere to the price lists proceeds to terminate distribution and/or sale agreement agreements it has concluded with the “defaulting” distributor; and the firm concludes exclusive distribution agreements.

CONTACT US: JAC MARAIS / PARTNER: COMPETITION LAW PRACTICE GROUP jac.marais@adamsadams.com ALEXIS APOSTOLIDIS / PARTNER: COMPETITION LAW PRACTICE GROUP alexis.apostolidis@adamsadams.com www.adamsadams.co.za

ABOUT ADAMS & ADAMS Adams and Adams, a full service law firm and the largest Intellectual Property (IP) law firm in Africa, provides services for all aspects of Competition Law, including advisory opinions, mergers and acquisitions and litigation in South African and Africa. Adams & Adams also provides highly specialised dispute resolution services in a broad spectrum of practice areas with a focus on contractual and commercial litigation, personal injury and medical negligence claims, employment, administrative law, consumer protection, banking and insolvency.

Adams & Adams also contributes to a number of multijurisdictional publications concerning IP, pharmaceuticals and Competition Law and its members are regularly asked to speak at conferences and seminars on these topics. The firm currently services an extensive client database, which include innumerable national and international corporates, boasting many of South Africa’s leading entities and multiple Fortune 500 companies.

AUGUST / SEPTEMBER 2012 49

AfriTrade now sales rep for GEC GLOUCESTER Engineering Inc (GEC) has appointed AfriTrade as their new sales representative in South Africa. AfriTrade will also represent GEC in the neighboring countries of Angola, Botswana, Namibia, Swaziland, Tanzania and Zimbabwe.

AfriTrade has been involved with the plastics industry for 12 years. Prior to filling their new role with GEC, AfriTrade has successfully represented Kabra Extrusiontechnik, Vihan and Prasad, amongst others. The company was started by Neil Smith, who has over 25 years of experience in the plastics industry. AfriTrade has a sales and service office in Cape Town and is in the process of opening offices in Johannesburg and Durban.

“We believe that the hiring of AfriTrade will help us increase market penetration for GEC in South Africa and the surrounding countries,” said Simon Jay, EMEA Sales Director for GEC. “In addition to expanding our business, we of course look to AfriTrade to provide excellent service and support to our existing customers as their local contact point and representative.”

THE ONLY INTERNATIONAL MOULD TEXTURING COMPANY IN SOUTH AFRICA j~{ i w z{ [ } w } ] ~w x{{ w z } | y{ ~{ ¢ { z | y {~{ { B w {B w z z { } w } | { NF {w ¤ w z {wz{ w } { { w w { | |wy{ | { w {B w y B x z } z y B { {B w { B y { w z y y w yw D

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• AFRITRADE TEL: 076 163 9627 OR EMAIL AT NEIL@AFRITRADESA.CO.ZA About Gloucester Engineering Co. Since its inception in 1961, Gloucester Engineering Co. Inc. has been a global leader in advancing quality and production limits in the plastics extrusion and converting market. GEC offers a range of innovative system and component solutions, for both new lines and retrofits, that provide customers a competitive edge in applications that include blown and cast film extrusion, foam and sheet extrusion, bag making and extrusion coating equipment.

CONTACT US: Standex Engraving South Africa | P.O. Box 83, Umlaas Road, 3730 Tel: 031 785 1247 | E-mail: dan@standexsa.co.za www.mold-tech.com / www.standex-engraving-design.com

FEATURE

Debtor defaults

now cause 30% of company liquidations

PART ONE

BY PAUL JOOSTE, COFACE SOUTH AFRICA details from the registrar of companies or COFACE South Africa, which has an legal identifiers, and checking information international presence in over 100 held by credit bureaus. Because countries, says debtor defaults now companies outside South Africa can be contribute to approximately 30% of more problematic, using an international company liquidations in SA. service provider with a worldwide database Providing credit is risky. Companies is an asset. need to carefully evaluate new customers and existing customers before providing Added value information credit or increasing credit limits.

To obtain a more up-to-date picture, ask “For exporters, it is even more difficult the customer receiving the exports if it collecting from debtors. Language barriers would be willing to submit its financial and different business cultures are making statements for assessment under a it difficult to collect overdue accounts, not confidentiality agreement. Companies to mention the cost of procuring a reliable are generally happy to provide accounts attorney,” says Coface South Africa senior or monthly manager portfolio management business, Paul Credit insurance removes the information for Jooste. task of an exporter having assessment on Some countries this basis, although do not operate on to check their client’s credit a refusal should a standard 30-day worthiness and, in the case not necessarily credit period for of a default, collecting the generate example. In contrast money in a foreign country a negative to larger firms, conclusion. smaller companies won’t have a presence in an overseas Shared information from policy holders country where they are trading or the Credit risk assessment is a continuous resources to employ a local lawyer. cycle. This is because the level of risk To ensure an objective assessment, attached to a transaction can change in the companies should use a number of course of just a few weeks. Therefore, the methods to determine whether a company evaluation of overdue accounts is critical. is a credit risk: This information can be used to refine credit assessment and, if appropriate, Verification of information reduce exposure to risk. with a third party These suggestions are critical to This includes all publicly available good risk management when trading on information about the importer, including credit, but can be time consuming. Credit the balance sheet and income statement; insurance companies have extensive court judgment information; press and experience in determining the level of risk media archives; confirmation of registration

attached to a particular trading partner and will back their assessment with their own money by providing debtor cover.

Most organisations are more willing to provide financial information to a credit insurer than to the supplier themselves, due to their concern of the supplier’s pricing policy should they see their profit margins, amongst other reasons.

Credit insurance removes the task of an exporter having to check their client’s credit worthiness and, in the case of a default, collecting the money in a foreign country.

Most local credit insurers do not have access to international credit information as would an international provider. They will also not have a presence or collection capabilities in that country. www.cofaceza.com

ABOUT COFACE The Coface Group, a worldwide leader in credit insurance, offers companies around the globe solutions to protect them against the risk of financial default of their clients, both on the domestic market and for export. In 2011, the Group posted a consolidated turnover of € 1.6 billion. 4,600 staff in 66 countries provide a local service worldwide. Each quarter, Coface publishes its assessments of country risk for 157 countries, based on its unique knowledge of companies’ payment behaviour and on the expertise of its 250 underwriters. In France, Coface manages export public guarantees on behalf of the French state. Coface is a subsidiary of Natixis whose share capital (Tier 1) was € 16.4 billion end December 2011. In South Africa, Coface provides credit protection to clients. Coface South Africa is rated AA+ by Global ratings.

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Marine debris body to advice Plasticsâ&#x201D;&#x201A;SA PLASTICSâ&#x201D;&#x201A;SA has held its ďŹ rst meeting of the newly formed ScientiďŹ c and Technical Advisory Panel on Marine Debris.

The Marine Debris Panel was created to look into the issue of persistent plastic debris in the coastal and marine environment and will advise Plasticsâ&#x201D;&#x201A;SAâ&#x20AC;&#x2122;s Sustainability Council and other stakeholders on awareness and research concerning marine debris in South Africa. â&#x20AC;&#x153;The problem is gargantuan and due to the unseen scale of the issue at sea it needs more attention in South Africa as our partners in other countries have already stepped up the effort to address this issue,â&#x20AC;? said John Kieser, Plastics/ SA environmental manager (coastal provinces). â&#x20AC;&#x153;Most people are only aware of the issue when it is on the coast, but it is a fraction of the amount of plastic already at sea. This dovetails into Plasticsâ&#x201D;&#x201A;SAâ&#x20AC;&#x2122;s other efforts to increase recycling of plastic products in South Africa and to design material not just for recyclability, but also in such a way that the packaging or parts of it does not become an entanglement problem.

What is also clear is that by focusing on the concern at sea, the matter of littering further inland is also addressed in a way.â&#x20AC;?

The Marine Debris Panel consists of two focus groups, Technical (awareness and monitoring) and ScientiďŹ c: John Kieser â&#x20AC;&#x201C; Plastics|SA (technical and scientiďŹ c) Prof Peter Ryan â&#x20AC;&#x201C; University of Cape Town (scientiďŹ c) Prof Colleen Moloney â&#x20AC;&#x201C; University of Cape Town (scientiďŹ c) Prof Henk Bouwman â&#x20AC;&#x201C; University of North West (scientiďŹ c) Ted Knott â&#x20AC;&#x201C; Wildlife Environmental Society of South Africa (technical) Michelle Wcisel â&#x20AC;&#x201C; Dyer Island Conservation Trust (technical) Wilfred Chivell â&#x20AC;&#x201C; Dyer Island Conservation Trust (technical) Douw Steyn â&#x20AC;&#x201C; Plastics/SA (technical) Wayne Munger â&#x20AC;&#x201C; KZN Wildlife (technical) Dr Brent Newman â&#x20AC;&#x201C; CSIR (scientiďŹ c)

AUGUST / SEPTEMBER 2012 51

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DESIGN

IT’S A FIRST !

Tritan thermoplastic copolyester from Eastman has never been used commercially in SA before JOBURG-BASED snapp Design is an award-winning distinctive lifestyle brand which aims to highlight contemporary design in South Africa by producing innovative products.

“The possibility of having a subtle impact on humanity through inspirational products was our motivation when we created our own brand,” said Jonathan Fundudis, owner and head designer at snapp Design.

When Jonathan and business partner Renko Nieman, with qualifications in industrial design and mechanical engineering respectively, formed snapp, their quest was encouraged by the process of discovery, redefining products through new understandings yet remaining true to self.

Intriguing and functional utensil to mix and serve salad.

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AUGUST / SEPTEMBER 2012

By using the extruded form of Plasticine and manipulating it by creating a gentle ‘s’ curve and separating the blended profile forms into tines, snapp Design were able to create an intriguing and functional utensil to mix and serve salad

“With our background in industrial design, the development of our ‘splay’ salad servers was a milestone for our company as it was the first plastic injection moulded product we produced,” said Fundudis.

Designed by David Holgreaves, an industrial designer who works for snapp Design, the inspiration behind the salad servers was derived from the material that was initially used to explore various concepts, Plasticine.

“By using the extruded form of Plasticine and manipulating it by creating a gentle ‘s’ curve and separating the blended profile forms into tines, we were able to create an intriguing and functional utensil to mix and serve salad,” said Holgreaves.

Once the development of the product was completed, snapp approached Plastichem for their expertise and technical support and set a brief to explore plastic polymers with which to produce the salad servers. The appropriate material that was defined is not only a first for snapp but a first for South Africa too, as this particular thermoplastic has never been used commercially here before.

A copolyester called Tritan from Eastman, supplied locally by Plastichem,

was the suitable solution. Wizard Plastics was commissioned to do the converting and found the copolyester effortless to process.

“We felt Tritan ticked all the boxes for the specified requirements of ‘splay’: the first being that it is FDA-approved as the product comes into contact with food, as well as being BPA-free. Secondly, for the convenience of the user, the material is dishwasher safe. From an aesthetic point of view, it has a clear base: therefore we are able to achieve vibrant colours from However, Tritan offers a variety added pigments as well as giving us the of processing, performance and option of being glass-clear with a high sustainability advantages over PC – and gloss finish. other clear polymers such as SAN and Because of the intricate design where SMMA – in a variety of housewares the tines split off applications. from the handle, the Eastman Tritan Because of the intricate inherent toughness of copolyester provides design where the tines Tritan prevents any a unique balance potential breaking split off from the handle, of these properties, of these delicate allowing you to the inherent toughness structures. create differentiated of Tritan prevents any “A material that products with potential breaking of these has certainly added compelling value: value to a simply delicate structures. glasslike clarity, beautiful product toughness, chemical where functionality and aesthetics blend resistance, processibility, hardness, BPAto create something special, it may be free, tintability, surface gloss, strength, a first for both companies locally – yet heat resistance, economics, design I’m positive it wont be the last,” added flexibility.

Fundudis. snapp Design:

Eastman Tritan™ copolyester Tritan™ builds on the versatility of its predecessors - including clarity, toughness and chemical resistance – to create a new standard for consumer and commercial housewares and sports bottles.

It’s natural to compare Eastman Tritan copolyester with polycarbonate (PC) because of its heat resistance advantages over traditional copolyesters.

www.snappdesign.com Plastichem:

www.plastichem.co.za Eastman:

www.eastman.com Wizard Plastics:

“The possibility of having a subtle impact on humanity through inspirational products was our motivation when we created our own brand.”

What is Plasticine?

PLASTICINE was formulated by art teacher William Harbutt of Bathampton, in Bath, England, in 1897. He wanted non-drying clay for use by his sculpture students.

Although the exact composition is a secret, Plasticine is composed of calcium salts (principally calcium carbonate), petroleum jelly and long-chain aliphatic acids (principally stearic acid). It is nontoxic, sterile, soft, malleable and does not dry on exposure to air. It cannot be hardened by firing; it melts when exposed to heat and is flammable at much higher temperatures.

Commercial production started in 1900 at a factory in Bathampton. The original Plasticine was grey, but the product initially sold to the public came in four colours. It was soon available in a wide variety of bright colours.

The original Plasticine factory was destroyed by fire in 1963 and replaced by a modern building. The Harbutt company continued to produce Plasticine in Bathampton until 1983. It is currently made in Thailand.

www.wizard-plastics.com

AUGUST / SEPTEMBER 2012

53

PRODUCTS

All-round protection for lines and hoses Chips have no chance with closed cable carrier by Tsubaki Kabelschlepp WOOD, metal or plastic chips entering into the cable space of cable and hose carriers can quickly result in costly problems. Carriers wear faster, the service life of the routed cables and hoses is shortened, and the availability of the entire machine or system is jeopardized. Tsubaki Kabelschlepp has developed an impressive solution for these types of environments with their cable carrier TKA55. The closed plastic cable carrier was awarded the Eco-Link label of excellence, and fulfils the very strict environmen-

The combination of features achieved by Thermolast® TPEs from Kraiburg, achieving a lightweight but strong structure, significantly increases the acceptance for wearing safety spectacles, making them a valued and attractive article of everyday use at the workplace

www.uvex.com www.kraiburg-tpe.com

tal compatibility standards of Tsubaki Group.

An optimized sideband and a cover contour with minimized gap dimensions effectively prevents functional faults caused by chips and dirt entering into or sticking to the cable carrier. The compact new cover design fits seamlessly into one another and reaches over the sidebands to form a compact, closed unit. They offer secure hold even under severe mechanical stresses, e.g. when used with hydraulic lines. The smooth, dirt-repellent contour of the side-

bands with their encapsulated stroke system prevents the intrusion of any foreign bodies.

The covers can be opened and removed easily on the inside or outside to load the cable carriers. The interior of the TKA55 can be modularly partitioned with various divider solutions for even cable distribution.

The optimized geometry of the chain links and a triple encapsulated stroke system allows the TKA55 to span extensive unsupported sections. The integrated gliding surfaces make the cable carrier the ideal

The perfect fit

compounds.

Innovative POM (polyoxymethylene) adhesion technology on the earpiece ends ensures that the spectacles are comfortable even when worn for long periods; anti-slip components provide for a secure fit.

The Thermolast K compounds used for the spectacles withstand all influences of the work environment, such as weather, UV radiation and scratches. Also, they pose no health hazard whatsoever to the wearer: the TPEs are free of polycyclic aromatic hydrocarbons, phthalates and allergens and are RoHS and REACH compliant.

THE features of Kraiburg’s Thermolast® K thermoplastic elastomer compounds make them ideal for a wide range of applications: not only are they suitable for all methods of processing conventional plastics, but are also soft to the touch and feature maximum adhesion for virtually unlimited freedom of design and function.

This was important when deciding to use them in the earpieces of the new Uvex ‘pheos’ safety spectacles: the goal of the development engineers was to introduce lightweight safety spectacles with a sporty design that offer optimum protection and high wearing comfort. The spectacles get their stylish design from the two-coloured, highly functional earpiece concept with TPE

• UVEX, WITH ITS HEAD OFFICE IN FÜRTH, GERMANY, SUPPLIES INTERNATIONALLY. THE PHEOS SPECTACLES WERE DEVELOPED IN THE USA.

Thermoplastic biomaterial for x-ray, CT & MRI imaging Solvay launches radio visible Zeniva® PEEK for implantable medical devices SOLVAY Specialty Polymers USA, LLC, has expanded its range of Zeniva® polyetheretherketone (PEEK) resins for use in implantable medical devices. A new radio visible PEEK-based material, Zeniva ZA-520, provides image contrasting capabilities for optimal visualization with x-ray, CT, and MRI imaging systems.

Zeniva PEEK is one of the four highperformance polymers that comprise the company’s family of Solviva® Biomaterials available for use in implantable medical devices. New Zeniva ZA-520 compound, which contains an image contrast additive, offers medical device companies all the performance benefits of Zeniva PEEK along with enhanced radio visibility.

Zeniva ZA-520 compound provides visibility of an implant without the artifacts 54

AUGUST / SEPTEMBER 2012

that are common with competitive metallicbased materials. The new compound is available in resin (for injection moulding) and rod stock which can be high-precision machined for production of a full range of sizes and configurations.

Zeniva PEEK offers numerous advantages over metals like titanium and cobalt chrome for applications such as intervertebral devices. The material offers many important benefits including biocompatibility, chemical inertness, and a modulus of elasticity that is close to that of bone. Based on biocompatibility testing to ISO 10993 standards, Zeniva PEEK demonstrates no evidence of cytotoxicity, sensitization, irritation, or acute systemic toxicity. www.solvayspecialtypolymers.com

New Zeniva ZA-520 compound, which contains an image contrast additive, offers medical device companies all the performance benefits of Zeniva PEEK along with enhanced radio visibility

Chip-tight to the end – The closed cable and hose carrier TKA55

by Tsubaki Kabelschlepp efficiently protects hoses and lines right up to the connection area from intruding chips and dust.

solution for long travel lengths. Integrated noise damping ensures that the cable carrier is running silently and with low vibration at all

times. The closed cable carrier by Tsubaki Kabelschlepp is available in six interior widths between 50 mm and 175 mm.

Best foot forward Innovative prosthetic foot wins medical design award AN innovative and affordable prosthetic foot, made with DuPont™ Hytrel® won the gold award in the rehabilitation and assistive-technology products category at this year’s Medical Design Excellence Awards (MDEA), a prestigious design competition for the medical technology industry.

The Niagara Foot is an affordable, effective and field-adjustable prosthetic that enables improved mobility for people who have lost lower limbs. The foot, in its next generation, is named the Rhythm Foot.

“The Rhythm Foot shows that high-performance and life-enhancing benefits can

The encapsulated triple stroke system of the TKA55 allows for extensive unsupported sections.

• KABELSCHLEPP IS REPRESENTED BY MAGQUIP IN SA, PHONE 011 473 2521

The Rhythm Foot is an innovative and affordable prosthetic made with DuPont™ Hytrel®

be delivered through materials science,” said Diane H. Gulyas, president, DuPont Performance Polymers.

DuPont received a 2012 MDEA certificate as supplier of the material used to produce the Rhythm Foot. The flexibility and durability of Hytrel, a polyester elastomer, is essential to the foot’s superior function and energy return.

The foot anatomically mimics biological foot action and its affordability means it is potentially accessible to many more people.

The ability to easily adjust the foot to fine tune its performance makes it dramatically different from existing dynamic prosthetic feet.

The foot is intended for use as a permanent option or as an interim prosthesis for the shower, swimming or for postoperative use. www.dupont.com

Filling hot dessert sauces

Lightweight 187ml PET wine bottles

LIOTTA dessert sauces are filled while hot, which places high demands on its packaging. A new 800ml bottle manufactured by the Austrian packaging specialist Greiner Packaging International meets these demands. The company opted for Greiner Packaging International and its Carinthian location of Wernberg. Since this spring, extrusion-blown bottles with a volume of 800ml have been supplied to Liotta from Wernberg. The new packs are made from PP specifically developed for the hot filling process. The core of production at Liotta is a fully-automatic, microprocessor-controlled unit that combines efficiency, hygiene and accuracy. At the beginning of 2012, the company was certified in accordance with the IFS (International Food Standard). All production processes are monitored at relevant check-points according to the HACCP (Hazard Analysis and Critical Control Points) concept, and verified.

Greiner Packaging International also runs an HACCP programme.

BRONCO Wine Co., Ceres, Calif., a major supplier of varietal wines, is establishing a strong position in the single serve, 187ml wine category with the adoption of lightweight PET bottles from Amcor Rigid Plastics. Bronco, the fourth largest winery in the U.S., recently made a major packaging switch from glass to further penetrate the retail and airline markets and capitalize on PET’s glass-like clarity, portability, sustainability advantages and reduced cost.

A unique barrier coating technology developed by Germany’s KHS Plasmax GmbH affords the 187ml PET container an extended shelf life. KHS Plasmax® Silicon Oxide (SiOx) barrier coating is a glass-like material which seals the container from the inside to protect the contents from oxidation. This ultrathin (less than 100nm) material is transparent and resists cracking, abrasion and delamination. It does not degrade over time nor limit the storage time for empty bottles. The barrier coating is easily removed during the recycling process and does not contaminate the recycling system.

www.amcor.com www.broncowine.com

www.greiner-gpi.com

AUGUST / SEPTEMBER 2012 55

Objet ups furniture fittings output Armac Martin boosts product range, wins orders with Objet Desktop 3D printer FURNITURE fittings specialist Armac Martin’s sales orders have risen steeply since installing an Objet24 Desktop 3D Printer at its facility in Birmingham, UK. “Since the introduction of 3D printing we are turning more of our customers’ ideas into new products and as a consequence we are winning more orders for our factory,” confirmed Paul McGrail, Armac Martin MD. Armac Martin designs and manufactures furniture fittings, many of which are bespoke designs specified by customers. The Objet24 Desktop 3D Printer, used to test new designs and produce product samples for customer approval, is enabling Armac Martin to save costs and service customers faster according to McGrail: Samples are with customers up to four weeks faster than before, sometimes in just a couple of days from the initial discussion. The company has also saved on tooling which would normally be required to produce the samples in metal.

PRODUCTS

Sealed Air selects Cardia sustainable resin LEADING global protective packaging manufacturer Sealed Air has selected Cardia Biohybrid™ sustainable resin for its new Fill-Air R5® inflatable packaging films.

The films are used in protective air-filled cushions and in ‘void-fill’ applications (as used in containers, for example), and need to achieve excellent sealability to ensure good air retention while protecting the packaged goods in transit. Besides that, the films must achieve high-speed processing on the Sealed Air range of Fill-Air® systems as well as.

Cardia Bioplastics, based in Australia, has been selling its polymers internationally. Dr Frank Glatz, the Cardia group’s MD, said the goals were to reduce the need for petroleum-based resins and maintain the packaging integrity of the Fill-Air® films.

David Weiss, business manager for Sealed Air said: “We focus on the total life cycle of our products and the products we protect. Our strategy involves under-

Two Objet 3D printed prototypes (left) with the original Armac Martin door handles (right)

Sleep tight!

A COMPLETELY new and thoroughly effective sleep and regeneration therapy has been introduced with the ‘inPulser’ by the German company Infrasonics. Greiner Assistec (Austria), a Greiner Packaging International division, produces the core element of this system – the Neurostimulator. Eurofoam – also from Austria – produces the pillow it is completed with. Bayer 04 Leverkusen and the German Aerospace Authority tested and were convinced by its effect.

Infrasonics commissioned Eurofoam to produce the sound pillow. Europe’s market leader in the production and processing of flexible polyurethane foams is well-known as a specialist for power napping solutions. Greiner Assistec scored top points in this project, in particular with its competences in plastics injection moulding, adhesive bonding and assembly. The housing for the loudspeaker system was designed in two parts comprising of a top and a lower shell. Both parts can be produced in a single injection moulding process using a single tooling unit.

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AUGUST / SEPTEMBER 2012

www.cardiabioplastics.com

Biohybrid resin – Sealed Air group is now using the Biohybrid™ polymers from Cardia Bioplastics in its range of Fill-Air R5® films used in air-filled cushion and void-fill applications

www.objet.com

www.greiner-gpi.com

standing the beginning and end of life, in addition to the performance during use.

The new Fill-Air R5 film addresses all of these areas.”

The new film is designed for use on the Sealed Air Fill-Air 2000 and Fill-Air Cyclone® packaging systems to quickly create air-filled cushions for void-fill applications. These systems are fast and easy to operate, delivering air-filled cushions on demand for excellent protection and efficient void filling, while reducing material and shipping costs.

Cardia Biohybrid resins combine renewable thermoplastics with polyolefin material to reduce dependence on finite oil resources and to reduce carbon footprint.

The renewable material is derived from corn crop grown for industrial use that will be replenished in the next growing season.

PRODUCTS

Eyes forward!

Zoff SMART frames made with SABIC Innovative Plastics’ Ultem resin meet the Japan Standard Association JIS B 7285 standard, whose testing includes 20 000 bending repetitions

INTERMESTIC Inc., of the USA, a specialty retailer of eyewear and accessories, has chosen tough, lightweight Ultem polyetherimide (PEI) resin from SABIC’s Innovative Plastics for the frames of its new line of Zoff SMART eyeglasses.

The tailored, aerospace-grade Ultem resin material solution helps meet Japanese consumer demands for fresh, new eyewear styles with exceptional long-term performance and feather-light comfort; by allowing Intermestic to eliminate titanium and aluminum from the material selection process.

The Ultem resin also provides exceptional flexibility, flame retardance, and resistance to chemicals, heat and ultraviolet

(UV) light, as well as greatly expanded design freedom, which enabled Intermestic to create stylish, eye-catching frames for sophisticated consumer appeal.

Ultem resin delivers a broad range of desirable performance properties for eyeglass frames. The material offers elasticity coupled with resistance to deformation, allowing the frame to be bent easily yet returned to its original shape.

Zoff SMART frames made with Ultem resin meet the Japan Standard Association JIS B 7285 standard, whose testing includes 20 000 bending repetitions (opening and closing the frame).

The SABIC resin’s dimensional stability ensures that the lenses are retained in

How to reduce noise from polymer roof sheeting A READER inquired about the problem of noise produced by the expansion and contraction of polycarbonate sheet in exterior applications. When exposed to sunlight, PC sheet produces creaking sounds as it expands while heating up and again as it contracts later in the day. We asked Colin Coetzee, former CEO of Ampaglas, SA’s leading manufacturer of polycarbonate sheeting, about this problem and he confirmed that the question was valid: PC expands and contracts at about 3 to 4x that of steel (polyethylene sheet has even more pronounced behaviour, being a factor of 5-6x that of steel). Even steel roofs make a noise in hot and cold weather, said Colin. The only way to resolve this is to make sure the screws have expansion allowance (holes must be at least 3mm oversized) and screws are not to be over-tightened with an expandable (PE or PU type) closure. Coetzee has now retired from the industry and moved to Robertson in the Western Cape.

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AUGUST / SEPTEMBER 2012

the frame, while heat deflection at high temperatures protects the frames even when left on a car dashboard in hot sun.

In addition to its intrinsic light weight of up to 50% vs. metal, Ultem resin is suitable for precision thin-wall moulding down to 1.2 mm, cutting weight even more.

The weight of the Zoff SMART frame is 9.4 g without the lens, which compares very favourably to metal frames typically weighing around 20 g. The material can be custom coloured to provide a wide range of aesthetic effects.

www.sabic-ip.com

The Phoenix, symbol of rebirth and

and using innovative processes to minimise

renewal, harbinger of a 21st Century

environmental impact, our commitment

message – regenerate, renew, recycle.

to quality and sustainability is evident

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giving without taking. Constantly scanning

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the horizon for opportunities to rejuvenate,

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

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for future generations

PRODUCTS

Cushion the impact!

Spring element made of low-emission resin acts as buffer during steering column adjustment BUFFER-stops made of the low-emission grade DuPont™ Delrin® 100PE acetal resin cushion the impact when mechanically-adjustable steering columns, from ThyssenKrupp Presta of Eschen, Liechtenstein, reach full horizontal adjustment.

Decisive factors in its specification were the material’s compliance with stringent emission levels demanded by some of Germany’s automotive OEMs for interior applications and its steel-like springiness. The material is also characterized by its vibration damping effect, its high notched impact strength and very good sliding properties.

The buffer-stop, injection-moulded in Delrin 100PE, takes up very little installation space with its 14 mm x 9 mm x 6 mm dimensions. Held by a rivet, it slides during adjustment of the steering column on metal guide rails until they reach their limit at the end of the adjustment range. Although the associated jolt may in some cases be hard, two small springs on either side of the buffer-stop are enough – thanks to the high stiffness and elasticity of the ma-

Testing by the SGS Institut Fresenius GmbH in Germany, in accordance with the VDA standard 275, confirms that all three low-emission grades of Delrin® meet the demanding emission requirements of the world’s major automotive manufacturers. (PHOTO: DUPONT)

When the steering column, supplied to a German automotive manufacturer as a complete system by ThyssenKrupp Presta, reaches full horizontal adjustment, then a small spring element, made of the low-emission grade DuPont™ Delrin® 100PE, cushions the impact. The emission level of volatile substances from this injection-molded part is below the particularly strict levels set by the German automotive industry

terial – to cushion the impact both mechanically and acoustically.

As a direct benefit of the excellent sliding properties of Delrin acetal resin, the buffer-stop will continue to move easily, softly and virtually inaudibly on the guide rails for the entire lifetime of the vehicle.

These high-precision parts that are characterized by their variable wall thicknesses, are produced in 16-cavity hot runner moulds and kept within a tolerance of just ±0.05mm.

The combination of high elasticity and stiffness as well as excellent sliding properties make Delrin acetal homopolymers a material of choice for applications requiring low weight and where elements are required to absorb high forces, levels of deformation and impact, as well as to continuously move both smoothly and quietly. www.dupont.com

When the heat is on!

HYDRAULIC & Automation Warehouse (HAW), a member of the Hytec Group of Companies, stockist of a wide selection of hydraulic hose, fittings, valves and hydraulic accessories, is now offering Fire Sleeve hose protection to the local market.

Fire Sleeve hose protection conforms to the aviation grade 1072 and features a braided structure, instead of knitted structure. Fire Sleeve offers continuous thermal protection of hoses, cables and electrical wiring from temperatures up to 260°C, and short-term protection up to 1200°C. Extremely flexible and conformable throughout its temperature and size range, 60

AUGUST / SEPTEMBER 2012

Fire Sleeve is highly resistant to hydraulic fluids, fuels and lubricating oils.

Due to the properties of Fire Sleeve, it is capable of shedding molten metal splash and may also be used for insulating hot oil, steam and other hot pipe surfaces, thereby reducing energy losses and at the same time, offering burn protection to personnel.

Fire Sleeve is suited to a variety of industrial applications and can accommodate the bundling of cables, hoses and electrical wiring, providing excellent thermal protection and abrasion resistance.

HAW carries large stocks of Fire Sleeve in all sizes and it is available from any HAW or Hytec branch.

• TEL: 011 281 3800, RICHARD VAN ROOYEN, HYDRAULIC & AUTOMATION WAREHOUSE Fire Sleeve is suited to a variety of industrial applications and can accommodate the bundling of cables, hoses and electrical wiring, providing excellent thermal protection and abrasion resistance

IDC – a new path to development Since 1940, the Industrial Development Corporation, South Africa’s largest development finance institution, has helped to build the industrial capacity that fuels the country’s economic growth, by funding viable businesses.

As the government’s key partner in revitalising the economy, the IDC focuses on priority economic sectors that offer the greatest potential to unlock job opportunities.

Our vision To be the primary driving force of commercially sustainable industrial development and innovation to the benefit of South Africa and the rest of the African continent.

Our mission The Industrial Development Corporation is a national development institution whose primary objectives are to contribute to the generation of balanced, sustainable economic growth in Africa and to the economic empowerment of the South African population, thereby promoting the econo omic prosperity of all citizens. The IDC achieves this by promoting entrepreneurship through the building nd enterprises based on sound of competitive industries an business principles.

What we do

Chillibush6703IDC

Through partnership, the IDC C provides funding in support of ment by: industrial capacity developm nd funding high-impact projects t Proactively identifying an t Leading the creation of viable new industries t Using our diverse indusstry expertise to drive growth in priority sectors t Taking up higher-risk fu unding in early-stage and high-impact projects

Telephone: 086 069 3888 Email: callcentre@idc.co.za To apply for funding online visit www.idc.co.za

What we offer you The IDC assists start-up and existing businesses with a minimum funding requirement of R1 million and a maximum of R1 billion.

Funding is offered across its mandated sectors under the following Strategic Business Units: t Agro-Industries t Chemicals and Allied Industries t Forestry and Wood Products t Green Industries t Healthcare t Information and Communication Technology t Media and Motion Pictures t Metal, Transport and Machinery Products t Mining and Minerals Beneficiation t Strategic High Impact Projects and Logistics t Textiles and Clothing t Tourism t Venture Capital Special funding schemes are available that address transformation and d entrepreneurial t i ld development l t (TES) (TES); ttopping i up equity it contributions from entrepreneurs (TES & RCF); and sector-specific schemes (horticulture, forestry, clothing and textiles, hospitals).

The IDC Gro-e-Scheme provides funding for projects from R1 million to R1 billion at prime less 3% for up to five years.

The IDC’s business support prog programme addresses non-financial support to entrepreneurs. eneur Assistance is provided with capacity building to improve mpro project viability.

If you have a project that can contribute to building South Africa’s industrial capacity and creating jobs, visit www.idc.co.za to find out in how the IDC can help build your opportunity.

PRODUCTS

A plastic that remembers Shape memory polymer developed from thermoplastic polyurethane A NEW thermoplastic polyurethane (TPU) developed by Bayer MaterialScience together with the BAM Federal Institute for Materials Research and Testing in Berlin, Germany, shows that plastics can also have a memory.

Parts made of such a plastic can be temporarily reshaped and fixed in this shape.

When heated to a certain temperature known as the switching temperature, they ‘remember’ their original shape and return to it virtually unchanged. In the case of the new product Desmopan® DP 2795A SMP, the switching temperature is approximately 40°C. The abbreviation SMP stands for the English designation for such plastics: Shape Memory Plastics.

“Given this special property, there are virtually no limits to the potential applications for the plastic,” said Jürgen Hättig, head of Business Development for TPU at Bayer MaterialScience. “We can imagine applications in areas ranging from mechanical engineering and the automotive, textile, sports and leisure industries to toy manufacturing and aerospace engineering.”

Possible applications include the easy repair of damaged bodywork parts using a hair dryer, remote temperature sensors, artificial muscles, hinges, self-loosening screws, packaging and shrink tubing.

Self-erecting film tunnels & counterfeit-proof labels The two partners recently submitted a patent application for a possible application in the area of functional film tunnels and self-erecting structures. Film tunnels in a field act like greenhouses and accelerate the growth of lettuces and vegetables so that these can be harvested sooner than is possible if allowed to mature in the classic manner under the open sky.

This is an opportunity for the new shape memory polymer. Profiles made of the new TPU plastic that have temporarily been brought into a flat shape are fastened to the transparent film. After the film has been laid on the bed, all that’s left to do is to heat the profiles to the switching temperature. They ‘remember’ their bent, permanent shape and pop up to form a half-tunnel, lifting the films with them.

The new material could also prove useful in product and brand protection applications. BAM has used the TPU product to develop labels with engraved and coloured quick response (QR) codes. The codes can only be read if the labels are in their

The new material could prove useful e.g. in product and brand protection applications.

The BAM has used the TPU product to develop labels with engraved and coloured quick response (QR) codes. The codes can only be read if the labels are in their permanent shape.

The labels are thus very well suited as a means of storing information to mark and identify products in a way that is very difficult to counterfeit

permanent shape.

Because the TPU material is free from plasticizers and antihydrolysis agents, it is also suitable for food contact applications.

It also boasts all the typical advantages of TPU, such as high abrasion resistance, flexibility and good chemical resistance. www.materialscience.bayer.com

TPV medical elastomers Low compression set in rubber-replacement applications like stoppers, seals and gaskets A SERIES of thermoplastic vulcanizate (TPV) elastomers spanning a wide range of hardness levels exhibits high purity and resilience for replacing rubber in medical applications and provides performance and processing advantages over other thermoplastic elastomers (TPEs).

Medalist® MD-200 Series elastomers range from ultra-soft 15 Shore A compounds to 80 Shore A grades, avoid the need for pre-drying because they are nonhygroscopic and have a light natural colour that allows efficient use of colorants. The compounds contain none of the extractable heavy metals commonly used in the curing of thermoset rubber. Because they exhibit lower oxygen absorption than non-vulcanizate TPEs, they give greater protection www.medalistmd.com

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AUGUST / SEPTEMBER 2012

to pharmaceutical contents when used in seals or gaskets for vials.

Medalist MD-200 compounds show greater resilience than other TPEs, perform well in high-temperature end uses and are more chemical-resistant. Most grades in the series adhere well to polypropylene in over-moulding.

Used commercially as a replacement for thermoset rubber in syringe stoppers, Medalist MD-200 compounds meet the requirements of ISO 7886 for single-use hypodermic syringes and exhibit a low coefficient of friction for consistent travel force in glass and polypropylene barrels.

• ADVANCED POLYMERS REPRESENTS TEKNOR IN SOUTHERN AFRICA

www.teknorapex.com

a brand of maag group

a brand of maag group

a brand of maag group

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

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

Power Factor Correction:

TECHNICAL

Reduce your electricity costs and free up capacity Power factor correction can save electrical energy costs and free up electricity supply capacity

BY ERIC SOLOT: ALPHA POWER SOLUTIONS CC JOHANNESBURG

Power factor correction of inductive loads An inductive load, such as a motor, draws current from the supply, which is made up of resistive components and inductive components.

The resistive components are: Loss current (small); Load current The inductive components are: Leakage reactance current (small); Magnetizing current 3

Up until fairly recently, the return on investment for power factor correction equipment in commercial and industrial applications was unacceptably long for most company.

Avoidance of wasteful electricity demand and consumption was in the past not given the attention it deserves and energy efficiency has only very recently become a strategic objective for most companies. The significant electricity tariff increases introduced in recent years have made investments in power factor correction very attractive for most commercial and industrial consumers.

1

What is power factor?

Power factor (also referred to as cosine phi) is the ratio between the active load power (KW) and the apparent load power (KVA) drawn by an electrical installation. It is a measure of how effectively the current drawn by the load is being converted into useful work output.

Magnetising Current

Motor Current

2

COSӨ =

kW kVA

=

kVA

PF

kvar

Ө Figure 1 – Power triangle

kW

All current will cause losses in supply and distribution systems.

A load with a power factor of 1.0 results in the most efficient loading of the supply and a load with a power factor of 0.5 will result in much higher losses in the supply system. A poor power factor can be the result of a significant phase difference between the voltage and current at the load terminals.

Poor load current phase angle is generally the result of an inductive load such as an induction motor, power transformer, lighting ballasts, welder or induction furnace. A poor power factor due to an inductive load can be improved by the addition of power factor correction.

A poor power factor can also be caused by a high harmonic content or distorted/discontinuous current waveform. A distorted current waveform can be the result of a rectifier, variable speed drive, switched mode power supply, discharge lighting or other electronic load. The power factor of a load with a distorted current waveform requires a change in equipment design or expensive harmonic filters to gain an appreciable improvement.

Figure 3 – Current vectors

The current due to the leakage reactance is dependent on the total current drawn by the motor, but the magnetizing current is independent of the load on the motor. The magnetizing current will typically be between 20% and 60% of the rated full load current of the motor.

The magnetizing current is the current that establishes the flux in the iron and is very necessary if the motor is going to operate. The magnetizing current does not actually contribute to the actual work output of the motor. It is the catalyst that allows the motor to work properly. The magnetizing current and the leakage reactance can be considered passenger components of current that will not affect the power drawn by the motor, but will contribute to the power dissipated in the supply and distribution system.

In the interest of reducing the losses in the distribution system, power factor correction is added to neutralize a portion of the magnetizing current of the motor. Typically, the corrected power factor will be above 0.95. Some municipalities penalize consumers with a poor power factor by charging them for excessive kvarh consumed (>30% of kWh consumed during the same period) and by doing so encourage them to reduce wasted energy by applying power factor correction.

Power factor correction is achieved by the addition of capacitors in parallel with the connected motor circuits and can be applied at the motor (static power factor correction) or at the distribution panel (bulk power factor correction).

The resulting capacitive current is a leading current and is used to cancel the lagging inductive current flowing from the supply to the inductive load.

Magnetising Current

P P I U

Work Current

U

Motor Current I

Line Current 180°

360°

540°

720°

wt

Work Current Capacitor Current Figure 2 – Phase angle 64

AUGUST / SEPTEMBER 2012

Figure 4 – Power factor correction current vectors

Bulk power factor correction When bulk power factor correction is applied, the power factor of the total current supplied to the distribution board is monitored by a controller which then automatically switches capacitor banks in a fashion to maintain a power factor better than a pre-set limit (typically between 0.95 and 0.98).

3.1

Figure 5 – Bulk power factor correction

Ideally, the power factor should be as close to unity as possible.

There is no problem with general correction operating at unity (even though this is usually not the most cost effective target power factor), but correction should not be applied to an unloaded or lightly loaded transformer. If correction is applied to an unloaded transformer, you create a high ‘Q’ resonant circuit between the leakage reactance of the transformer and the capacitors and destructive high voltages can result.

Static power factor correction As a large proportion of the inductive or lagging current on the supply is due to the magnetizing current of induction motors, it is easy to correct each individual motor by connecting the correction capacitors to the motor starters.

REDUCED PROFITS

CAPACITY LIMITS

MAXIMUM DEMAND EFFICIENCY

3.2

INCREASED BILLS

Help your clients reduce their maximum electrical demand with our trusted products and services.

Figure 6 – Static power factor correction

• 24 month guarantee on our product range • The possibility to enter into service contracts • We provide training if necessary

With static correction, it is important that the capacitive current is less than the inductive magnetizing current of the induction motor.

In many installations employing static power factor correction, the correction capacitors are connected directly in parallel with the motor windings. When the motor is Off Line, the capacitors are also Off Line.

When the motor is connected to the supply, the capacitors are also connected providing correction at all times that the motor is connected to the supply. This removes the requirement for any expensive power factor monitoring and control equipment.

• Free audits of electrical installations • Flawless aftermarket service • A stock of spare parts and complete assemblies • Estimated ROI is between 6 – 18 months

PART II OF THIS ARTICLE, FOCUSSED ON INDUSTRIES THAT BENEFIT MOST FROM POWER FACTOR CORRECTION, WILL BE PUBLISHED IN OUR NEXT ISSUE. Eric Solot, author of this report, holds a Master of Applied Engineering (Electrotechnology) from the University College in Ghent (Belgium). At present he is the managing director of Alpha Power Solutions, which specialises in power factor correction and harmonic filtration, based in Johannesburg

Tel: +2711 615 4640 • Fax: +27866 542390 Cell: +2772 546 5185 E-mail: eric@alphapowersolutions.co.za

References: [1] Wayne, S., ”Power Factor Correction: a guide for the pant Engineer”, Eaton Corporation, June 2006, pp 3-18. [2] Lex Electrix, www.lexelectrix.com Bibliography: Wakileh, G.J., Power system harmonics, Springer-Verlag, Berlin, 2001

www.alphapowersolutions.co.za

www.alphapowersolutions.co.za AUGUST / SEPTEMBER 2012

65

EQUIPMENT

3 new LG injection moulding machines at First National Battery PMS PLASTICS recently installed an LG850, LG550 and LG350 injection moulding machines at First National Battery in East London.

The LG850 and LGH550 are the ‘M’ Series – two platen energy saving models.

The two platen machines with a highly accurate hydro-mechanical locking system provide high efficiency and low running costs. The machines require 26% less space, less hydraulic oil and with the easy to maintain LG unique clamping mechanism, it enables the clamp pressure to increase via four short stroke high pressure clamping cylinders, improving cycle times due to short pressure build up times. The four short stroke clamping cylinders are situated in the stationary platen.

The HICOM 5000 closed loop controller provides statistical process control with a selection of 10 parameters for last 100 shots, a self-diagnosis alarm and monitoring, internal memory and external access through USB, as well as ethernet access.

“The on-time delivery was followed up with a site visit by the competent commissioning team who ensured a quick and smooth start-up of each machine and pro-

Stuart Sutherland (PMS Plastics technician) with happy First National Battery clients Clint Liebrum (technician), Martin van Rensburg (production manager) and Elvis Sakuba (plant manager) where three new LG injection moulding machines were recently installed

vided the necessary training of the machine operators and maintenance teams. These machines are well suited to our high volume moulding requirements,” said Martin van Rensburg of First National Battery.

PMS Plastics has represented LG in South Africa for 15 years. The Korean-manufactured LG machines are becoming well

liked in the SA market for their high quality, reliability, user friendly operation and cost efficiency.

LG supply full electric machines up to 550 tons and hydraulic machines with servo driven pumps up to 3 000 tons clamping. www.pmsplastics.co.za

Multotec install LG850 injection moulding machine Multotec’s John Keegan and Wolfgang Langenstein with Peter Wolber of PMS Plastics at Multotec where an LG850 ton injection moulding machine was recently installed by PMS Plastics. The high-tech LG850 ton injection moulding machine is designed and supplied with a 1 300 ton injection unit to achieve a 9kg shot weight in polyurethane with a special screw design for this application to prevent frictional heat and degradation of the material.

This is the third LG installed by PMS Plastics at Multotec for the production of polyurethane components for the mining industry locally and abroad. Wolfgang Langenstein of Multotec said that the high accuracy and reliability of the LG machines met the specification demands required on their polyurethane products, many of which have large metal inserts which are overmoulded. He added that PMS Plastics are the ideal partners for the supply of their machine requirements because of their technical expertise, exceptional back-up and after-sales service.

www.pmsplastics.co.za

High end performance with a small footprint The Objet30 Pro is a 3D printer that combines the accuracy and versatility of a high-end rapid prototyping machine with the small footprint of a regular desktop printer and unique capabilities, including the industry’s highest level print resolution and seven different 3D printing materials.

In fact, the Objet30 Pro is the world’s only desktop 3D printer capable of printing in clear transparent material, high-temperature resistant material and polypropylenelike material. Featuring a compact built 66

AUGUST / SEPTEMBER 2012

tray size of 300 x 200 x 150 mm, the Objet30 Pro is ideal for the rapid prototyping needs of companies producing consumer goods and electronics and medical devices, as well as Rapid Prototyping service bureaus and design consultancies.

Built with 7 materials – 12-year-old Sebastian O’Hara displays the model car built with 7 different Objet materials on the Objet30 Pro. Each part was printed separately so the car could be built as a kit.

www.objet.com

Brand-New Premium Injection Moulding Machines

All Electric Injection Moulding Machines

UNIQUE Two-Platen Injection Moulding Machines

Toggle Injection Moulding Machines with Energy-saving Servo System

EQUIPMENT

New CVe monitor for tracking mould activity Mould management device provides useful insights into mould’s performance PROGRESSIVE Components, a leading global supplier of mould components for production tooling, has introduced an electronic mould monitoring device called the CVe Monitor™.

This mould management device monitors more than just mould cycles completed. It gathers specific data which can either be viewed by toggling through the mould monitor’s onboard display screen or by downloading the information by connecting the monitor to a PC via the monitor’s miniUSB port.

The following data is shown on the display and can be toggled by pressing a button on the CVe: total cycles cycle time: life of the tool cycle time: past 25 000 cycles activity percentage: life of the tool activity percentage: past 25 000 cycles The monitor includes a resettable cycle count meter that can be used for short run verification of cycles versus parts manufactured.

Maximum utilization of the monitor’s full potential is attained when information is

With the new CVe and On Demand Software, various reports can be generated which provide useful insights into the mould’s performance

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AUGUST / SEPTEMBER 2012

downloaded. This allows various reports to be generated which provide useful insights into the mould’s performance.

To access this facility, the ‘On-Demand’ software needs to be downloaded. This software is provided free of charge with the purchase of each monitor.

The software’s reporting capabilities mean that users can generate and save reports locally or on a network. Users also have the option to send emails to management, customers or OEM’s when the reports are run. The reports are saved in both encrypted Excel and PDF formats. The reports use data from the CVe to provide weekly views of the mould’s performance, including the cycle times, up and down times for the life of the tool and the last 25 000 cycles.

An important feature is that mould drawings, along with any other relevant documents, can be stored on the monitor’s 2 GB internal flash drive. This means that wherever in the world the mould is, there is a complete record of its history, as well as making all technical drawings easily accessible to whoever may need them.

Confidentiality is protected by means of

a password control feature. This is of immense benefit to OEM’s who use different moulders to produce their goods.

To facilitate ‘retro-fitting’ the CVe requires the same pocket size as the popular parting line mechanical CVPL CounterViews and it has a battery life of 50 000 hours (5 years).

The software works with Windows XP or Windows 7 platforms and can be installed on any computer in the plant. The user of the software needs to register and will receive a username and password to run the software throughout the company.

• View the new YouTube video at: www.youtube.com/watch?v=n5_ 9icvkLaE&feature=plcp

• FOR MORE INFORMATION, CONTACT MOULD & DIE SOLUTIONS AT TEL: 021 555 2701

www.m-d-s.co.za www.procomps.co.za

Delivering Superior Solutions Supplying the industryâ&#x20AC;&#x2122;s broadest range of general mould components

moulds & components runnerless solutions die sets Contact: Mould & Die Solutions surface ďŹ nishing P.O. Box 669, Edgemead 7407, Cape Town, South Africa customized solutions Tel: 021 555 2701 | Fax: 021 555 2707 | info@m-d-s.co.za www.dmeeu.com

www.m-d-s.co.za

EQUIPMENT

Wilvic uses Wittmann Battenfeld machines Wilvic Plastics manufactures high-tech products with 34 injection moulding machines, most from Wittmann Battenfeld WILVIC Plastics, a Battenfeld customer of long standing based in Krugersdorp, relies entirely on Wittmann Battenfeld for hightech applications.

Established in 1993, Wilvic Plastics is a producer of complete system solutions in plastics, ranging from product design, prototyping and in-house mould making up to mass production of the plastic components.

Its main outlets for the products are in the mining industry, with renowned customers such as Caterpillar, but some components are also sold to the automotive, security, irrigation and sanitary installation industries.

The main market is the US market, with roughly 60% share of total sales.

The remaining sales are realized primarily in the domestic market and in Australia.

The company’s production floor space is 2 400 m², with an additional 700m² taken up by in-house mould making and 800m² for office space. The company is owned by the Bogdanovic family and employs 43 associates.

Wilvic’s top priorities in manufacturing its products are high standards of quality and precision. The company is striving for competence and top performance in all areas, whether it is customer relations, continuous innovation based on latest trends in the industry, or production processes. Stateof-the-art technology is used in all areas, too, from product development and mould making to injection moulding.

Wilvic processes high-quality polymers.

Many of the components are fiberglassreinforced. The high quality of the raw material used ensures that the products meet the most stringent demands in terms of moisture absorption, abrasion resistance or thermal resistance.

For 2013, the ISO-9001-certified company is now seeking environmental certification as well. This will make Wilvic one of the first injection moulding plants in South Africa to obtain such certification.

Wilvic manufactures its high-tech products with a total of 34 injection moulding machines, most of which are from WittEdmund Kirsch, area sales manager at Wittmann Battenfeld, Stephan Janse van Vuuren, production manager at Wilvic Plastics, Barend Bogdanovic, plant manager at Wilvic Plastics and Keith Reading, sales director with Mouldplas

70

AUGUST / SEPTEMBER 2012

Wilvic manufactures high-tech products with a total of 34 injection moulding machines, most of which are from Wittmann Battenfeld

mann Battenfeld. Bogdan Bogdanovic, the company’s managing partner, has divided his production programme into ‘high-tech’ and ‘low-tech’ sectors. Battenfeld machines are used exclusively in the high-tech sector. The newer machines all come from Wittmann Battenfeld’s hydraulic HM series, with clamping forces ranging from 110 to 180 tons.

“For our high-tech sector, Wittmann Battenfeld is definitely our first choice,” said a satisfied Bogdanovic.

In view of rising energy costs, Wilvic will focus more on energy-efficient production in future and is considering the use of machines from Wittmann Battenfeld’s

ServoPower series. These are hydraulic machines incorporating a highly dynamic servo motor with a substantially higher degree of efficiency and an internal gear pump with fixed displacement, instead of a three-phase motor with constant speed and an adjustable axial piston pump.

In this system, the delivery is regulated exclusively via the motor speed and it is possible to set the optimal speed required for every operating point. www.wilvic.co.za www.wittmann-group.com

VISIT US AT

AFRIMOLD 10 -12 OCTOBER 2012

Affordable Technology for Packaging

EQUIPMENT

ENGEL SHOWCASES

challenging applications & innovative technologies Every aspect of injection moulding technology and automation solutions highlighted of the Engel duo 1500 combi M injection THE international injection moulding moulding machine and its high degree industry gathered in Austria on 13 and of automation and process integration 14 June for the Engel Symposium 2012 impressed the visitors. in St. Valentin and Linz. With challenging No less impressive was the production applications and innovative technologies of extremely thin-walled and at the same showcased on 18 exhibits, presentatime highly decorated laptop covers in a tions on the megatrends of the future clean room, the high degree of integration in injection moulding, an exhibition by offered by a production cell for manufacpartner companies, and the HL Awards turing lamp housings including a bead Ceremony 2012, the Engel Symposium seal on a minimal is a highlight of the footprint, and the year.

More than 2 700 guests two-metre tall mould More than 2 700 from 35 countries visited for manufacturing guests from 35 the exhibition which wringing forks for countries visited floor mops using the exhibition which covered automotive, the Engel gasmelt covered automotive, technical moulding, process, which can technical moulding, teletronics, packaging and be implemented on a teletronics, packagmedical business units. comparatively small ing and medical Engel victory injection business units. moulding machine with a clamping force This was the first time that Engel demof just 500 tons thanks to the use of tieonstrated the Dolphin process for manubar-less technology. facturing premium automobile interior Two machine types celebrated their parts with a ‘Softtouch’ surface at its first airing at the symposium: the electrilarge-scale machine factory in St. Valenfied variant of the Engel duo large-scale tin; the first series production application machine, Engel e-duo, and the new, allhad not been launched until autumn last electric Engel e-mac injection moulding year. More than anything else, the size

machine for maximum precision requirements in technical moulding. This was topped off by giving visitors a peek into the future of automotive lightweight construction in the production of brake pedals using an innovative insitu polymerisation technology on a prototype machine.

www.engelglobal.com

ENGEL HL Awards 2012 Innovative applications on tie-bar-less machines THE ENGEL HL Awards 2012 were presented in June against the backdrop of the Engel Symposium 2012. This year’s prize winners leveraged the benefits of tie-bar-less technology, mainly to achieve greater cost-efficiency in production. The HL Awards in Gold, Silver and Bronze went to Volkswagen in Wolfsburg/Germany, O.C.S.A. in Creazzo/Italy and Anton in Zalaegerszeg/Hungary.

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AUGUST / SEPTEMBER 2012

The HL Awards are Engel’s acknowledgement of excellent applications with Engel tie-bar-less injection moulding machines. The tie-bar-less technology that Engel introduced to its Victory series of machines more than 20 years ago not only supports particularly efficient production concepts, but also inspires more and more users to develop totally new process ideas. This year’s jury members closely

scrutinized the deployed technologies, the progressiveness of the applications and the economic benefits compared with legacy machines. The jury comprised Prof Dr Christian Bonten, head of the University of Stuttgart’s Institute of Plastics Technology (IKT), Thomas Bründl, CEO of starlim/sterner in Marchtrenk/Austria, and Joachim Rönisch, the publisher of K Magazine, Hanover.

Thinwalled laptop covers and Kindle eReader covers produced using Engel technology

TELETRONICS Engle e-duo 500

PACKAGING

Caps and buckets made using Engel technology

Engel s-duo 700

AUTOMOTIVE

Engel e-victory 120 combi Brake pedals produced using an innovative insitu polymerisation technology on a prototype machine

Engel viper 90

MEDICAL Medical applications

Engel e motion 100 T

AUGUST / SEPTEMBER 2012

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EQUIPMENT

ENGEL HL Awards 2012 Multiple, optimum use of tie-bar-less benefits

The HL Award 2012 in Gold went to Volkswagen who used the benefits of tie-bar-less technology in two different ways in the production of components for fuel filler door modules for the Golf, Golf Estate and Golf Plus models. Firstly, the extremely large moulds use the whole of the mould fixing platens’ surfaces and even protrude beyond them at the sides.

Secondly, the large grippers on the handling robot can reach into the mould space without interference. Both factors ensure that the production cell has a minimal

SILVERD AWAR

Twice as fast as the competitor

It’s not just in the automotive industry, but also in packaging that fast cycle times are a precondition for good competitive ability. Tie-bar-less technology inspired mould maker and injection moulder O.C.S.A. from Creazzo/Italy to create a unique mould design. Thanks to it, O.C.S.A. produces coffee capsules for

ZE BRON D R A W A

Clamping force of 400 tonnes instead of 600

The HL Award 2012 in Bronze went to Anton in Zalaegerszeg/Hungary.

Thanks to tie-bar-less technology, Anton can now position no less than four injection units on a machine with just 400 tons clamping force, while at the same time combining multiple-component injection moulding with insert-placing technology.

footprint. At the same time, free access for the robots considerably reduces the cycle time.

The awardwinning production cell comprises two tie-bar-less injection moulding machines – ENGEL victory 750/400 tech and ENGEL victory 1050/400 tech – and two Kuka KR 60 multiple-axis robots. To produce the inserts for the fuel filler doors, first the base body made of 30% glass fibre reinforced (PICTURE: VOLKSWAGEN)

GOLD D AWAR

Volkswagen uses the whole of the mould fixing platens’ surfaces. This factor ensures that the production cell has a minimal footprint.

polypropylene is injected. The second machine then adds an EPDM seal.

Technologically, a very challenging combination of materials!

espresso machines by illycaffè twice as fast as its competitor, and was thus able to secure contract awards for more of illycaffè’s projects.

The core of the capsule, the polypropylene and TPE coffee holder, is injected on an Engel victory 1350H/200W/220 combi machine in a 32+32x rotary plate mould.

The key to reducing cycle times is cooling the hard component. To accelerate this process, in-house mould making replaced

the cooling water supply hoses with thicker pipes. They jut out upward through the mould area and are directly connected to the cooling unit. Because there are no tiebars in the way, the pipes can easily follow the motion of the rotary plate.

The Engel victory 1050H/330W/ 200V/400 combi is used to produce housings for electric manual tools by Anton’s largest customer, Bosch. After an Engel viper 20 linear robot has insert-placed the metal inserts into the 2+2x rotary plate mould, the left and right housing shells are first injected from green PP GF30. Following this, the mould rotates to a second position where the three following components are applied in a single step using corepulls:

first the red Bosch label (PP GF30), then black, and finally grey TPE S on the handle surfaces. Anton requested quotations for various injection moulding machine types for the mould, which measures 1250 x 910 x 900 mm. Legacy machines were planned with clamping forces between 600 and 800 tons. With the tie-bar-less 400 tons Engel victory machine, Anton not only saved on cost of investment, the smaller machine also offers savings in ongoing operations.

Tie-bar-less technology inspired O.C.S.A. to create a unique mould design. Thanks to it, the injection moulder produces coffee capsules for espresso machines by illycaffè twice as fast as its competitor. (PICTURE: ENGEL)

Thanks to tie-bar-less technology, Anton can now position no less than four injection units on a machine with just 400 tons clamping force, while at the same time combining multiplecomponent injection moulding with insert-placing technology (PICTURE: ENGEL)

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Efficient wear resistance in twin-screw extruders

Plasma transferred arc welding system and traverse and axial closed system with counter-rotating twin-screw extruder

EQUIPMENT

Minimize naturally occurring adhesive wear in counter-rotating twin-screw extruders, increase machine service times greatly KRAUSSMAFFEI Berstorff is offering even more efficient wear resistance for all parallel and conical twin-screw extruders with the plasma powder arc welding process (PTA) for coating the top-root edges of counterrotating twin screws.

“By using the plasma powder arc welding process, we can minimize the naturally occurring adhesive wear in counter-rotating twin-screw extruders and increase the machine service times enormously”, stressed Dr Liebhold, head of extrusion technology at KraussMaffei Berstorff. “A software developed specially for this application permits continuous welding even with incline changes in the flights to be coated and welding of the runouts depending on the selected screw geometry”, he explained.

The system is designed for machining screws with diameters ranging between 43 and 184 mm. Counter-rotating twin-screw extruders transport the material almost completely in the axial direction in an enclosed chamber system.

The speed and pressure conditions caused by the system result in a so-called

calendar effect with flow conditions in the comb-out area of the screws. In both the solids and melt handling areas, this calendar flow under high surface pressures leads to adhesive wear effects resulting from the screw shafts being pushed apart, and the screw shafts can only support themselves on the barrel. As a result of this abrasive wear mechanism, permanent damage can be caused during manufacturing to screws and barrels, which can sometimes lead to a complete failure of the system.

Optimized welding process parameters such as the current in relation to the screw outer diameter and the customized composition of the flux powder ensure the production of PTA-molybdenum hard facing that is practically free of cracks with the lowest possible dilution especially in the outer areas of the weld.

KraussMaffei Berstorff also offers a PTAproduced high-wearing surface coating for all parallel twin-screw extruders with tungsten-carbide reinforcement. Tungstencarbide coatings are used for heavy adhe-

sive wear, for example for the processing of natural fibre composites for decking profiles. As a result, the KraussMaffei Berstorff twin-screw extruders for WPC processing achieve much higher service times compared with standard machines which, depending on the formulation and correct operation of the machines, can add between 12 000 and 20 000 operating hours.

• PLASTIC & CHEMICAL TRADING CC ARE THE SA AGENTS, TEL: 011 483 3015 www.kraussmaffeiberstorff.com

Efficiencies in raw material identification PLASTICS fundis gathered recently at a workshop presented to showcase the abilities of a handheld plastics analyzer. Hosted

by United Spectrometer Technologies, the workshop focused on the next generation of handheld spectrometers that can be used for raw materials identification.

Michael Gallagher, product and applications specialist with Thermo Fisher Scientific shared best practices using cutting edge United Spectrometer Technologies MD Jacques le Roux with Thermo Fisher Scientific’s Anna Tshwene and guest speaker Michael Gallagher

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technology to achieve efficient raw material identification in a GMP environment.

The Thermo Scientific microPHAZIR PC is a handheld NIR material analyzer designed for rapid onsite plastic material identification. The 1.25kg analyzer is battery powered and completely self-contained for portable analysis and is ergonomically designed for the expert and non-technical user alike. The handheld unit can identify most Alan de Haas and Donnevan Espag of Mpact Recycling attended the workshop

www.ustech.co.za

common plastic types, including PLA, PET, PP, PS, ABS, PI, PSO, PE, PPS, TPV, PTT,PC, PMP, PBT, PA (nylon), PETG, SAN, EVA, PB, PPO, CA, PMMA, PUR, PI, PVC, PLA, Ionomer, Styrenic terpolymer, Elastomer, POM, Nylon and ABS. Nilesh Ozarkar (Extrupet recycling), Steve Benjamin (remade recycling) and Vasant Aher (Extrupet recycling) were also there

The Thermo Scientific microPHAZIR PC is a handheld NIR material analyzer designed for rapid onsite plastic material identification

where quality is action

A-PET

Inventor, Esben Østergaard, who won the Invention and Entrepreneurship in Robotics and Automation Award for the robot arm UR5 he designed for Universal Robots

www.universal-robots.com

Robot wins global prestige award Makes it possible for small and medium-sized companies to automate production THE Danish robot arm UR5 from Universal Robots recently won an international robot competition at the largest global automation exhibition ‘Automatica’ in Germany.

Hundreds of companies in Europe and Asia use the innovative robot from Universal Robots to automate their production.

In a cutthroat competition with robots from Japan, USA, Germany and England, the UR5 robot from Danish Universal Robots has now been elected as the world’s most innovative robot. The award is also recognition of the record growth that the company behind the new flexible robot arm has obtained since 2008.

An expert jury from the two international

robot organizations, The International Federation of Robotics (IFR) and IEEE Robotics and Automation Society, paid tribute to inventor, Esben Østergaard, by handing him a statuette for Invention and Entrepreneurship in Robotics and Automation Award.

The UR5 is safe, user-friendly and flexible because it can work side by side with employees, increasing efficiency. The jury did, however, also stress the fact that Universal Robots has made it possible for small and medium-sized companies to automate production, because the UR robots are both reasonable in price and easy to implement in production.

Global breakthrough In 2011, Universal Robots really had their breakthrough when the company sold 400 robots globally. This year, the robot producer expects to at least double sales.

The name of the company behind the innovative robot in itself explains why the robots are so popular. The robots are universal in the sense that everybody is able to use them all over the world and for all kinds of automation tasks, and that is exactly what one of the inventors, Esben Østergaard, set out to do.

• UNIVERSAL ROBOTS IS REPRESENTED

BY PLASQUIP IN SOUTH AFRICA.

All-round success

rial hang-up in the bin has been completely eliminated as there are no edges, recesses or indentations where material can get trapped. Faster material changeMOTAN-colortronic has made another investovers are possible as there is no need ment – this time in the enhancement of the Luxor series of dryers. The drying bin access door is now for elaborate cleaning. The 2mm thick stainless steel drying bin surface in contact rounded, aligned with the outer contour and the radius of the drying bin respectively. In addition, the with the material is glass pearl-blasted and smooth. Laser welded joints with totally flat insulation of all thermal sections of the drying bin weld beads and point connections support has been reengineered. These design improvean even, fast and clean trouble-free matements apply to all drying bins between 100 litre rial flow. and 2 400 litre capacity.

The fully insulated drying bin – including With the new design the possibility of mate-

the door – is made of a temperature-resistant insulating material which is several centimetres thick. As an encapsulated insulation pack, it hermetically seals the cavity between the inner and outer wall of the drying bin. The door hinges are adjustable to guarantee hermetic sealing – without any loss of heat – and can be turned 180° in two stages. The first 90° closes and locks the door; the second stage seals the door.

• PLASQUIP IS THE SA AGENT FOR MOTAN-COLORTRONIC The door hinges on the newly designed Luxor dryers are now adjustable to guarantee hermetic sealing – without any loss of heat.

(PHOTOS: MOTAN-COLORTRONIC)

www.motan-colortronic.de

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EQUIPMENT

All-in-one affordable CAD/CAM solution MIDRAND-based TDM Solutions has introduced the ZW3D 2012 all-in-one, CAD/ CAM solution to South Africa. ZW3D 2012 has over 180 000 users in 80 countries worldwide. And at a fraction of the expected costs, more design and manufacturing companies in SA can access this powerful integrated CAD/CAM solution.

Unlike other packages on the market ZW3D 2012 Premium Edition offers a full solution, solid design, assembly design, hybrid design, drafting design, reverse engineering, core & cavity design and sheet metal. Included is 2-axis lathe and 3-axis surface machining modules. An optional module can be added if multi-axis machining is needed.

ZWsoft who publish ZW3D 2012 has had over 100 new features added and 140 improvements on its predecessor.

ZW3D 2012 is easy to use and comes with ‘Show-n-Tell™’ tutorials which help to shorten the learning curve and reduce training costs.

ZW3D 2012 can import all major CAD file formats including SolidWorks, NX, Catia V4 & V5, Inventor, Pro/E, IGES, STEP, STL, DXF & DWG. ZW3D 2012 can also export Parasolid & 3D-PDF formats.

ZW3D 2012 can be used in any industry that requires design and manufacturing

capabilities. Typical industry sectors would be tool die & mould, small engineering shops, reverse engineering agencies, industrial design companies, the mining sector and educational institutes.

ZW3D 2012 is available for a free 30 day trial. A student version has also been launched, giving students the ability to

improve their CAD/CAM skills, which can only help with their future employment opportunities.

• TEL: TDM SOLUTIONS AT 011 805 9627 www.tdmsolutions.co.za

Photo realistic CAD rendering of a crankshaft using ZW3D

AUGUST / SEPTEMBER 2012 79

Take the first step on the road to innovation!

The Department of Chemical Engineering at the University of Pretoria offers honours degrees (following on bachelors’ degrees) that will prepare materials scientists, engineers and polymer technologists to play an active role in the commercial world and the field of applied research.

Lectures are presented in block format to accommodate students working full time. A wide range of postgraduate modules are available, including: • • • • • •

Chemical Product Design Polymer Materials Science Polymer Processing Polymer Additive Technology Fluoromaterials Science Carbon Materials Science and Technology

Through the Institute of Applied Materials (IAM), students have access to excellent facilities for their postgraduate training.

The Department of Chemical Engineering offers research opportunities towards masters’ or PhD degrees for suitable candidates. These include: • •

MEng/PhD (Chemical Engineering) MSc/PhD (Applied Science)

Enquire about the availability of bursaries.

Course brochures can be downloaded from the websites of the Institute of Applied Materials (www.iam.up.ac.za) and the Department of Chemical Engineering (www.up.ac.za/chemeng).

For more information please contact: Prof Walter Focke • Email: Walter.Focke@up.ac.za • www.iam.up.ac.za

Universiteit van Pretoria • University of Pretoria • Yunibesithi ya Pretoria Privaatsak • Private Bag X20 Hatfield 0028 • Suid-Afrika • South Africa • Afrika Borwa Tel: +27 (0) 12 420 4111 • Fax: +27 (0) 12 420 4555

www.up.ac.za/chemeng

mediachef4381

By specialising in Advanced Materials and in particular Polymer Technology, prospective students are assured of study leadership by acclaimed academics with strong research records in their fields of expertise.

EQUIPMENT

Crystallization of PET masterbatches IR Batch, more than just a perfect crystallizer AT NPE 2012, Kreyenborg Plant Technology of Germany displayed its latest addition to their IRD technology, the IR Batch, which uses very efficient shortwave infrared radiation instead of hot air as a heat source.

Thus, conventional, agitated mixing crystallizers were not reliable, as the start-up of such systems with amorphous material is a definite challenge. These conventional systems were originally built for semicontinuous silo-type ‘FiFo’ principal working crystallizing jobs in the injection moulding industry. In these semi-continuous processes, the start-up of the system is not an issue, as For several years now, Infrared-Drum Dryers have proven themselves as superior crystallized material for the start-up process is usually available. technology in many PET applications.

When these systems are started with Advantages include energy efficiency, short residence time and flexibility through its abil- amorphous MB, the material tends to clump in the cone due to ity to handle various poor agitation in this material forms and IRDs are often used in area which often properties. Last but PET applications such as results in broken or not least, ease of opjammed mixing cast film, thermoforming eration and reliability elements. As a result, of crystallization and sheet, strapping and the system has to be drying are advantages recycling production. completely disasreported most often by sembled, cleaned, IRD customers. and fi xed, and in these cases the small lot of IRDs are often used in PET applications MB material is negatively affected, unable to such as cast film, thermoforming sheet, be sold at a higher price. strapping and recycling production.

These issues do not exist when IRDs are Continuous Kreyenborg IRDs are also used for crystallization. successfully installed as crystallizers of Most colour masterbatch companies colour masterbatch. Normally, companies using continuous IRDs in PET masterbatch are interested in a system for crystallization of colour masterbatch off-line. The are running large quantities and do not market mainly asks for small quantities and change the colour very often. The smaller throughputs. Different colours, different model IRD-A is also used as a crystallizer loads of colour, and the final converting for quantities up to 150 kg/hr. Frequent application for the masterbatch require differcolour changes require adaptations to enent processing conditions for the crystallizer. able proper and sufficient cleaning as well Due to their reaction to heat, IR radiation as quick start up times. in particular, some colours can be heated Often, colour masterbatch companies quickly over the glass transition point while are asked to deliver hundreds of different others require a very gentle and rather long colours and sometimes very small lots.

Conventional crystallizer with limited agitation in the lower cone

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Example of a continuous working IRD with 2 temperature zones

heating process in this part of the processing window.

A small IRD-A type for small throughputs offer little options to adjust the process according to various MB types. It offers only one temperature zone and a limited drum rotation speed adjustment.

Even larger machines of an IRD-B type offer a maximum of three different temperature zones for running a temperature profile but only a small process window for the drum rotation speed as well. Therefore, the amount of mechanical mixing energy cannot be varied through the length of the drum.

Materials which are difficult to heat up can really challenge the processing limits of such continuous IRDs. Such difficult materials may include specific colours and/or PET copolymer types for special applications. The IRD may not offer enough residence time or mechanical mixing energy to produce perfectly crystallized granules, for example ‘twins’ of granules which were melted together can exist.

Processing sequence of the IR Batch System

Challenging applications no problem These really challenging applications can be perfectly crystallized in the IR Batch.

As opposed to the continuous working IRD types, the IR Batch operates in a discontinuous or batch principle. A defined batch size is fed into the drum and then heated up by a preset temperature profile to the crystallization temperature while the drum is rotating. After finishing the crystallization, the material is discharged by a counter-rotational movement of the drum.

Once emptied, the machine is ready for the next crystallization cycle and can be fed with new material again.

The discontinuous process has some important advantages for materials which are difficult to crystallize. As it is not directly linked to an inline process, the drum rotational speed can be increased as high as possible to achieve an excellent mixing of the pellets during the critical crystallization phase.

The typical sequence is a fast heating of the PET Masterbatch in the beginning.

Therefore the drum rotation is relatively slow and the IR radiator power of the system is higher. Once the material gets to the critical crystallization temperature of between

104°C and 135°C, the speed of the drum is increased to a much higher rotational speed to avoid any clumping of the material and assure a very good cross mixing of the material. After the material is through this critical section, the radiator power or heat can be increased again to finish the crystallization process, meanwhile the drum rotation can be slowed down again. Typically this crystallization process is finished after 15 – 20 min, depending on the material.

After finishing the process, the IR Batch will automatically discharge the drum and begin the sequence again by refilling the drum. A pneumatic slide gate will open the dosing hopper and new material will be loaded into the drum. While the crystallization/heating process starts again, the machine will meanwhile refill the dosing hopper for the next cycle. With the operation of the IR Batch running automatically and in a closed loop, the throughput rate (i.e. for 14kg/15min) will result in a total average throughput of 54kg/hr.

The automatic refilling as well as all relevant parameters for the different temperature ramps is fully integrated in the state-of-the-art Touch Screen control. Once parameters and temperature profiles are

Variables drum speed, radiator power and process time in the IR Batch process, total process time 17 minutes

found for a specific material, theses settings can be saved as recipes in the control system.

A common side-effect of highly-filled masterbatches is the electrostatic loading of the pellets. In order to avoid sticking from electrostatic effects, Kreyenborg Plant Technology developed a special Masterbatch Package for the IR Batch which includes an ionization unit to neutralize electrostatic loadings within the material.

Besides the critical behaviour of highlyfilled or modified PET masterbatches, the cleaning of processing equipment can be one of the most important and time consuming details. The IR Batch can be opened completely, and the Infrared module slides out on a separate frame. The drum with the simple mixing elements has no hidden spots and can be cleaned easily with a vacuum cleaner or compressed air. This enables the operator to have a very quick change from one material to another. www.kreyenborg.de

Easy access to the drum for cleaning purposes

Automatic refilling of the machine

AUGUST / SEPTEMBER 2012 81

EQUIPMENT

No compromise!

Optimal contact between rollers and film yields improved transparency WITH its new Multi-Touch polishing stack, battenfeld-cincinnati, Bad Oeynhausen/ Vienna, has developed an optimal solution for film producers who are not prepared to compromise on film quality even at high line speeds. Thanks to an absolutely innovative concept, a high degree of transparency, excellent flatness and an extremely even film thickness can now be achieved for a great variety of materials, such as PS, PET or PP, as well as EVA or laminated products.

As is the case in all sectors of the extrusion industry, outstanding efficiency in the production process is also a must in film extrusion today. The demand is for higher and higher output with optimized product quality. Criteria such as transparency, high gloss and flat-ness are vital factors especially in the production of packaging sheet for thermoformed products. At the same time, film and sheet producers want to be able to respond as flexibly as possible to the diversity of incoming orders.

The main idea in the design of this new polishing stack was derived from the assumption that infinite line speeds could be realized with an infinite number of gaps for final calibration. In the Multi-Touch polishing stack, this idea has been put into practice with a two-roll polishing stack for preliminary calibration, followed by three,

five or seven rolls for final calibration.

The first two rolls come with a large diameter to minimize deflection. They are followed by smaller rolls to achieve flat, stress-free film and sheet. In contrast to the well-established, conventional threeroll polishing stacks, the Multi-Touch polishing stack provides absolutely even, consistent contact between the film and the rolls even at maximum line speeds, which ensures optimal cooling of both sides of the film.

The greater number of post-cooling gaps provides a reliable means to even out film thickness tolerances. In this way, film can be produced with maximum transparency, excellent flatness with only few orientations, and a uniform thickness profile.

Thin-walled chill rolls with small roll diameters are used to facilitate easy handling, with a simultaneous increase in cooling performance. They offer the same hardness and line load capacity as conventional rolls, yet operate significantly more efficiently.

The first Multi-Touch polishing stack has been up and running on the production floor of a major German film producer since autumn 2011. The polishing stack is now available with up to 7 post-cooling chill rolls for outputs of up to 3 600 kg/h for PP.

On the left is film produced with a Multi-Touch polishing stack.

On the right is film produced with a conventional polishing stack

The new Multi-Touch polishing stack from battenfeld-cincinnati yields excellent film quality attributes together with high output

www.battenfeld-cincinnati.com

3.7m wide HMW sheet POLYMER INDUSTRIES of Alabama, USA, one of the fastest growing polyolefin sheet manufacturers in the world, has recently installed a new sheet line from Davis Standard of the USA to produce HMW (high molecular weight) HDPE, PP, pipe-grade HDPE and LDPE sheet. Polymer Industries is one of the only suppliers in the industry to offer 3.7m-plus wide HMW sheet as well as equal sales in both HDPE extruded sheet and UHMW pressed sheet.

The new Davis-Stanard system produces HMWHDPE sheet at rates of 635kgs/hour for making commercial dump truck liners. The system features a 200mm Thermatic® air-cooled extruder, DSB® barrier screw with cavity transfer mixer, temperature control panel, screenchanger package and 4,1m) EX-M-PLAR® sheet rollstand system. The EX-M-PLAR gives the ability to achieve exacting sheet thicknesses with an individual roll drive system and motorized gap control. Most of the sheet coming off the line is produced in 12mm thicknesses.

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AUGUST / SEPTEMBER 2012

www.polymerindustries.com

www.davis-standard.com

Passionate about the plastic industry Service team for after sales service and training

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EQUIPMENT

Krones’ SuperClean-PET-flake process is able to produce flakes at a high degree of purity, which can be directly used for making new bottles

Closed-circuit recycling From container feed right through to finished, decontaminated flakes from a single source FOOD company Stute Nahrungsmittelwerke in Paderborn, Germany, is rigorously pursuing its eco-friendly strategic thrust. After investing in three wind farms, a biogas system and several solar power installations that together cover more than 30% of Stute’s own energy requirements, this privately owned company will in future also be able to completely recycle PET material.

The beverage plant will commission Germany’s first PET recycling line from Krones in August. The SuperClean-PETflake process is able to produce flakes at a high degree of purity, which can be directly used for making new bottles. Conventional processes, by contrast, require additional steps for creating food-grade recyclate.

Stute plans to feed back both PET bottles and preforms into its bottle production operation. This also includes bottles that have already come into contact with product. The recycling process washes and decontaminates the rejected PET,

guaranteeing its suitability for future foodgrade applications.

From the recycling line directly into the injection-moulding machine The PET materials waiting to be recycled are first comminuted and then fed to the washing system’s storage silo. The PET recycling line is made up of the following main components: washing module, decontamination module, plus the peripherals.

The line is installed on two different levels: the washing module and the decontamination module are spatially separated, with the latter located directly next to the existing injection-moulding machines for producing preforms.

The decision in favour of Krones was an easy one for Stute, since Krones is the only manufacturer able to offer a complete system, from container feed right through to the finished, decontaminated flakes from a single source, thus reliably eliminating any interfacing problems.

In response to market trends, Stute is shifting its container priorities, progressively away from carton packaging and towards PET containers. Stute has meanwhile been operating 13 PET lines in its Paderborn facility. Since 2009 Stute has rigorously opted for Krones’ technology when it comes to new investments.

To start with, there was its first PET-Asept variant, which was followed by two lines with a Contipure preform decontamination feature. Thanks to the innovative preform decontamination feature, consumption figures for both energy and media have been significantly reduced as compared to container treatment.

In mid-2012, what will then be the firm’s fourth Krones line will start operation – this one, too, a PET-Asept line. There are plans for further investments with Krones to replace some relatively old lines.

www.krones.com

Intelligent control THE new Illig Intelligent Control Concept was a main feature at Illig’sOpen House hosted at Heilbronn in May where more than 200 guests had the opportunity to gain insight into technology and performance of current Illig automatic roll-fed machines.

The Illig Intelligent Control Concept (Illig IC) is a modular design allowing the user to make optimum use of the various possibilities. The compatible modules are geared at improving productivity and reproducibility, as well as the availability of a thermoformer and/or a complete thermoforming line.

Using the TermoLineControl module, all machine components of the production line can be called up and programmed centrally on the touch panel at the forming station. At the same time various auxiliary functions are available for process optimization and reduction of tool installation times.

To improve process reliability, a compensation control balances the effects of changing environmental influences during ongoing production. Using the new sas-up® (self-adaptive start-up) module results in a considerable reduction in material consumption during start up and commissioning of new tools.

The Illig Intelligent Control Concept (ILLIG IC) is rounded off by interlinking a production line with the NetService. In this way service engineers from Heilbronn can look into all line components via internet, diagnose errors and correct setting-related malfunctions rapidly.

Participants at the Illig open house show were especially interested in the demonstration of the new Intelligent Control Concept which allows utilization of the entire potential of today’s servo-driven thermoformers to the full extent

www.illig.de 84

Lightweighting in trucks

MATERIALS

First truck charge-air duct in Ultramid A PLASTIC compound from BASF has, for the first time, found use in the chargeair section of a commercial vehicle. The charge-air duct on the DD13®/DD15® truck engines is one of the first large production applications for the new polyamide (PA) grade Ultramid® A3W2G6.

The multifunctional oil intake module is also manufactured from a BASF polyamide. The designation DD13/DD15 covers a range of high-performance truck diesel engines with a displacement of about 13 and 15 litres, respectively.

Compared to its aluminium predecessor, the lightweight charge-air duct made from the BASF polyamide is 1.8 kg, or 50 %, lighter.

The high heat-aging resistance of the polyamide 66 specialty Ultramid A3W2G6 is confirmed by its performance in pulsating pressure tests of the component at 140°C. The charge-air duct must survive 3 000 hours of pressure fluctuations between 0.4 and 3.5 bar.

The oil intake module on the DD13/ DD15 is made from Ultramid® A3WG7 and, in addition to the oil intake connection and oil supply line, incorporates an integrated check valve. In the component test, the aged material has to withstand over

Smoothly does it Double-acting seals on crane hook are answer for world’s largest crane vessel TRELLEBORG seals are helping ensure smooth lifting operations for the world’s largest crane vessel as it goes about its business of installing production equipment for deepwater oil and gas fields.

The crane vessel is Heerema Marine Contractors’ Thialf, a huge semi-submersible barge equipped with two super-cranes.

Underwater operations mean that the hook assemblies are exposed to seawater.

Measuring more than six meters in height, each four-prong hook assembly rotates

www.ultramid.de

The charge-air duct made of heat-stabilized Ultramid A3W2G6 (left) and the multifunctional oil intake module for the DD13 and DD15 truck engines are manufactured by ElringKlinger for Detroit Diesel Corporation, the American truck engine and component manufacturer in the Daimler Group. In both cases, lightweight plastic components replaced the considerably heavier metal counterparts

10 million oil pressure pulsation cycles between 5 and 13 bar at 120°C. In long-term testing of the check vale, 500 000 cycles must be withstood in the presence of a sharp oil mixture that contains not only aged engine oil but also fuel components.

Ultimately, a truck is expected to drive about 1.2 million km. In this part, substitution of Ultramid for metal and the high degree of functional integration resulted in cost and weight reductions of 0.8 kg, or 50 % per part.

on a massive roller bearing packed with lubricating grease.

Trelleborg’s seals are required to protect the bearing from seawater and resulting corrosion and wear to the metal parts, while allowing the smooth rotation of the hook shaft.

The solution chosen was Trelleborg’s Turcon® Roto Glyd Ring®, which is widely used in other industries. An unusually large size was required, with a diameter of 1.8 metres.

The Turcon Roto Glyd Ring is a seal made of Trelleborg’s proprietary PTFE (polytetrafluoroethylene) based material.

The characteristics of PTFE have won it wide use in industrial applications, especially in environments where movement is involved. It has a low friction coefficient and

is stick-slip-free, thus allowing smooth transition from a stationary state to movement.

In addition, it is a long-lasting material that displays excellent chemical resistance and fluid compatibility.

As pressure from liquids such as seawater or oil increases, the pressure with which the O-Ring pushes the PTFE seal onto the counter surface also increases, thus ensuring that the seal remains tight

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www.trelleborg.com

The Turcon Roto Glyd Ring PTFE seal is energized by an elastomer O-Ring

MATERIALS

Fluorochemical research supports SA’s beneficiation strategy University of Pretoria tasked to develop a fluoro-polymer capability for local industry the ability to produce hydrogen fluoride THE University of Pretoria’s Institute of and fluorine gas, have long since been Applied Materials (IAM) has been tasked crossed by the local nuclear industry and to bring existing technology residing partnerships have been established with at the South African Nuclear Energy several international companies.

Corporation Limited (Necsa) in the field of PTFE, PVDF, FEP and PFA to the Exciting developments in University of Pretoria in order to develop dealing with PTFE scrap a fluoro-polymer capability for local The SARCHI Chair in Fluoromaterials: industry.

Science and Process Integration was esProf Philip Crouse who heads the tablished in the Department of Chemical research chair at IMA says that South Engineering at the University of Pretoria Africa has fluorspar resources to last in 2007, and has been functioning under 300 years and the technical know-how the IAM umbrella since 2010. and commercial expertise to support full One of the most recent research scale beneficiation of this mineral. highlights has been in the way industry Mineral beneficiation has been identideals with polytetrafluoroethylene (PTFE) fied as a national priority to create emscrap. PTFE, often better known by its ployment and to drive economic growth DuPont trade name Teflon, which is in South Africa. In support of government non-reactive, has a very low coefficient policy, the SARChI Chair in Fluoromaof friction, a very high maximum working terials at the University of Pretoria’s temperature and is Institute of Applied water repellent.

Materials (IAM) has Most of the research conducted This is partly been researching is aimed at developing the because of the the beneficiation South African chemical strength of its carof fluorspar as part industry, with a particular focus bon-fluorine bonds. of government’s on conversions, raw material The material has Fluorochemical supply, polymer modification many industrial Expansion Initiative and product design for polymer applications and is (FEI). systems and materials often used in conAccording to tainers and pipes Prof Crouse, South for reactive and corrosive chemicals.

Africa has the world’s second largest fluPTFE in general is not melt-processible orspar (CaF2) deposits but has exported and products are cut from large blocks. up to 95% of this high-potential mineral The scrap produced in the process could in the past, despite considerable fluorinenot be reused up to now. The Fluororelated scientific and technological materials Chair at IAM has very recently expertise existing locally. To supply the developed a process, an extension of rapidly growing local and export market, work originally done by Necsa-Pelchem, the main barriers to market entry, namely

Prof Philip Crouse who heads the research chair at the University of Pretoria’s Institute of Applied Materials

through which PTFE scrap can be processed and reused as fresh resin.

In the process, scrap from this highly versatile material is thermally cracked to produce the constituent monomer in sufficient purity to be directly polymerized - without any additional distillation or further purification steps. The virgin resin has been sintered successfully; in other words, it has been heated to form a coherent mass without melting it. While the process still needs further tweaking, the first results of this technique developed by post-graduate students of IAM have proved to be highly exciting. www.aim.up.ac.za

Laser transparency for engine cooling THE new Ultradur® LUX is being used in an air flap control unit, an unusual serial application in automotive construction. Motor developer Precision Motors Deutsche Minebea (PM DM), based in Villingen-Schwenningen, Germany, is using this highly laser-transparent and easily laser-weldable BASF plastic from the PBT family to make the housing cover of its novel control module. This small actuator consisting of gears, an electric motor and an electronic unit serves to control the air flaps in motor vehicles, thus contributing to better aerodynamics and lower CO2 emissions. The highly lasertransparent PBT Ultradur LUX accounts for stiffness and dimensional stability, even in damp environments. The product’s key characteristic is its high transparency toward near-infrared light in the 800 to 1100 nm wavelength, precisely the crucial range for penetration laser welding. The improved transparency to laser light means that this material can be welded faster than other PBT grades available on the market. The processing window is considerably wider and the risk of damage to the material is much lower.

The grade used here, Ultradur LUX B4300 G4, is reinforced with 20% glass fibres.

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www.ultradur.de

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SACMI, SIPA collaborate in preform closure project Features special combination of preform neck finish and lightweighted caps SIPA (Zoppas Industries Group) and Sacmi, two of Italy’s most innovative companies operating in the packaging sector, have combined their skills in the search for a new solution in the combination of PET preforms and closures that provides advantages for processors and end-users alike.

The collaboration, which has been given strong backing from the two companies’ managements, headed by Enrico Gribaudo (SIPA) and Giuseppe Lesce (Sacmi) respectively, combines SIPA’s substantial experience in the development of preforms, with that of Sacmi in caps and closures. A combined development team incorporates a level of technical competence considered unrivalled anywhere in the world.

The fruit of this collaboration is a new solution – with the acronym S.U.P.E.R. – featuring a special combination of preform neck finish and lightweighted caps that solves several key problems associated with the operation of a cap on the neck of a PET bottle, with results previously not thought possible.

S.U.P.E.R. stands for Sustainable, Unique, Productive, Easy, and Reliable – the five key benefits of this innovative solution: Sustainable, because the closure will be lighter than the average of alternatives on the market today, reducing the processor’s consumption of raw materials and energy; Unique, because this is a proprietary solution, protected by patents, that will provide benefits exclusive to those who adopt it; Productive, because it reduces the time and cost of equipping production lines – when switching between containers for various types of products, including water, soft drinks, and aseptically filled drinks, very little modification is required to lines for either preforms or closures (the latter produced with SACMI’s compression process, which already offers reduced tooling times and high production speed); Easy, because the solution provides the consumer with a bottle that is easy to open. The guaranteed positive LB angle – the leak angle is greater than the bridgebreak angle, a feature not available on the market today with current closure solutions – gives the perception of a closure that is very easy to open; Reliable, because the special tamper evidence system provides an immediate breakage of the security strip, rendering the bottle secure, with no risk of blow-off. www.sacmi.com

MATERIALS

SABIC’s Qrystal high-clarity PPs save time, energy Designed with unique flow behaviour to produce parts faster, lower energy consumption TO MEET the need of converters for materials that deliver better finished products and that can be produced cost-effectively, SABIC has developed two new high clarity SABIC® PP Qrystal polypropylenes.

These random copolymers, typically for injection moulding, were specially designed with unique flow behaviour, providing processors with the flexibility to produce parts faster and with lower energy consumption.

SABIC PP QR674K, with a melt flow rate (MFR) of 40g/10min, was typically developed for more sensitive food contact applications, owing to its improved organoleptic performance (low odour). Typical target applications are caps and closures, houseware, kitchenware and food/nonfood containers.

SABIC PP QR678K, with its high MFR

of 80 g/10 min, is better suited to production of parts with complex shapes and/ or long and narrow flow paths. Customer trials have shown around 15% higher flow than a standard PP random at the same MFR level, allowing machines to run at lower processing temperatures and 15% faster cycle times, potentially decreasing production costs.

SABIC has a broad package of PP random copolymers that provide solutions for a wide range of applications, providing a combination of good transparency with lower conversion costs. The SABIC PP Qrystal range, which was launched in 2010, now comprises four grades, with MFRs ranging from 25 to 80 g/10 min.

All SABIC PP Qrystal grades can be processed at much lower temperatures than many other commonly used copolymer polypropylenes from the market, leading to significant reductions in cycle time and energy consumption, as a sustainable solution to decrease the moulded article carbon footprint. They also have a good balance of impact strength and stiffness and enable customers to produce parts with no loss of transparency or aesthetics.

The SABIC PP Qrystal grade family is produced both in Europe and the Middle East and can be delivered globally. www.sabic.com SABIC’s Qrystal® polypropylene grades achieve new levels of optical performance ... as well as energy savings for converters

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MATERIALS

‘Drop-in’ solution for PA12 extruded, injected components TECHNYL eXten alternative to PA12 with grades for tubing, flexible hoses, injection moulded parts TO bring high-performance, economical solutions to the automotive and the manufacturing industry quickly in the midst of the PA12 crisis, Rhodia Engineering Plastics, member of the Solvay Group, is proposing its Technyl® eXten PA6.10 product as a drop-in solution for a variety of applications where PA12 is typically used.

Rhodia’s application experience to date, developed in partnership with its customers since 2010, show that Technyl eXten PA6.10 is a versatile alternative to long chain polyamides such as PA12. For many existing PA12 applications, Rhodia brings a true drop-in solution that will do the job. That’s more important than ever as PA12 supplies continue to tighten.

“Compared with PA12, Technyl eXten grades offer customers a range of technical and cost-benefit advantages, in addi-

tion to their environmental performance,” said Pierre-Emmanuel Lucas, new business project director for Rhodia Engineering Plastics.

“Working closely with our customers, we have the ability to provide a quick solution for many different applications where PA12 is now used, and where supplies of that material are in jeopardy going forward,” he added.

Introduced to the market in 2010, Technyl eXten grades are available for both extrusion and injection moulding and are specifically suited to the manufacture of flexible tubes for the transportation and industrial industry, and glass reinforced moulded parts such as fittings and adapt-

ers for the engine fuel systems market.

In addition, it is partially based on raw materials from natural origin and shows an improved environmental profile.

Blow moulded turbo air duct in Technyl B2

Injected turbo air duct in Technyl HP

www.rhodia.com

Glow-in-the-dark masterbatch saves lives!

Allows emergency medical personnel quick access to treat wounds WHEN the inventors of the Rip Shears* Ripper received feedback from medics in the field that their life-saving product would be even more effective if it glowed in the dark, they and co-developer ICON Injection Moulding (based in Phoenix, Arizona, USA), sought assistance from custom compounder RTP Company because of their expertise with visual effects.

Attached to a standard pair of trauma shears, the Rip Shears Ripper allows emergency medical personnel to quickly slice through multiple layers of clothing,

equipment and body armour to access and treat wound sites. While medics loved the snip and rip performance of the product, a glow-in-the-dark version would allow even faster usage at night or in low light conditions.

“This was a very specific request; we hadn’t done a glow-in-the-dark product before,” explained Steve Kleitsch, ICON’s co-owner. “But, we were aware of RTP Company’s expertise with visual effects, so we brought them in for assistance.”

The Rip Shears Ripper uses an RTP

200 Series glass fibre reinforced nylon 6/6 compound. It provides the stiffness needed to allow the blade to stay on track and flow through fabric cleanly. If the plastic were to flex, even slightly, bunching of the fabric could slow down the ripping process.

For the glow-in-the-dark version, called the Rip Shears Firefly, RTP Company supplied a phosphorescent glow-in-the-dark colour masterbatch that combines with the reinforced nylon compound during moulding. Advanced glow-in-the-dark technology imbues the material with an ‘afterglow’ effect that lasts for up to 8 hours, which is about 10 times longer than traditional GITD technologies.

“RTP Company got the glow-in-thedark effect and product performance right on the first try, right out of the gate,” said Kleitsch. “The inventor loved it and we began production immediately.” www.rtpcompany.com www.iconinjectionmolding.com The Rip Shears Firefly – RTP Company supplied a phosphorescent glow-in-the-dark colour masterbatch that combines with the reinforced nylon compound during moulding 92

AUGUST / SEPTEMBER 2012

MATERIALS

Tough PVC elastomers for electric vehicle charger cable Cost-effective alternatives for insulation and jacketing TWO Flexalloy® PVC elastomer compounds from Teknor Apex Company provide manufacturers of charger cable for electric vehicles (EVs) with cost-effective alternatives in terms of both insulation and jacketing.

The new compounds are Flexalloy 89504-90, a 90 Shore A formulation for insulation, and Flexalloy 9610-78 for jacketing, with Shore A hardness of 78.

The materials exhibit brittle points of -46 and -38ºC, respectively, and are both rated for a maximum continuous operating temperature of 105ºC (typical physical, electrical and flame properties appear in the accompanying table).

Unlike standard flexible vinyl, Flexalloy compounds are based on ultra-high molecular weight PVC resin. They exhibit improved toughness, abrasion resistance and low temperature properties and pro-

vide elastomeric resilience and resistance to compression set, according to Mike Patel, wire and cable industry manager for the Vinyl Division of Teknor Apex in the USA. The compounds can be processed on standard PVC equipment.

“Teknor Apex developed these two new Flexalloy products especially to meet the requirements of UL Type EVE for the high production volumes and rugged end use performance posed by EV charger cable,” said Patel. “They provide cost-effective alternatives to premium-priced elastomers such as TPUs.” • THESE TEKNOR APEX MATERIALS ARE SUPPLIED IN SOUTH AFRICA BY ADVANCED POLYMERS. www.teknorapex.com

Resealable closure for infusion bags New application of medical compounds from KRAIBURG TPE COMPOUNDS from the Thermolast® M product range of the German TPE specialist Kraiburg TPE will soon be used in medical products made in Bolivia: Matriplast S.A. based in La Paz will use this advanced product to manufacture high-quality infusion bag closures for the South American market.

Matriplast produces closures for infu-

sion bags that are made from the special medical series Thermolast M. These materials are certified for medical applications in most countries. In addition, they can be processed very efficiently and hygienically. The TPEs can be sterilised in hot steam up to 135°C and are available in hardness grades between 35 and 45 Shore A. They also have resealing properties which makes them ideal for use in infusion bags: As the TPE diaphragm is extremely elastic, it immediately seals the septum when the infusion line is removed from the bag.

Bolivian company Matriplast produces closures for infusion bags that are made from the special medical series Thermolast M from German TPE specialist Kraiburg TPE 94

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When push comes to shove In contrast to a conventional septum made in rubber, TPE has the added advantage that it can be processed by two-component injection moulding bonded with PE and PP. There is thus no need for the manual assembly of the rubber bag closures, so time and money can be saved while the risk of non-conforming bags is minimised.

The new solution also does away with costly storage of the closure components and contamination of the septum is simply impossible. While rubber components always pose a risk of contamination with potentially hazardous substances produced in the chemical reaction, such contamination cannot occur with thermoplastic elastomers, as they are not cross-linked.

www.kraiburg-tpe.com www.envases-matriplast.com

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MBT South Africa Unit 14, Eastwood Office Park, 11b Riley Road, Bedfordview.

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082 801 7373 082 901 0477 083 769 4543

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Carlotta Stafford 082 600 7403 Paul Gripper 082 456 6659

Borealis coating protects Nord Stream gas pipeline

BOREALIS, a leading provider of chemical and innovative plastics solutions, is extending the high-level protection benefits of its Borcoat™ steel pipe coatings to Europe’s longest offshore natural gas steel pipeline, Nord Stream. The advanced performance

offered by Borcoat will help secure the integrity of the pipeline over its minimum 50 year service life.

Nord Stream is a steel pipeline project routed under the Baltic Sea, designed to transport natural gas a distance of 1 224km from the Russian city of Vyborg to the European exit point in Lubmin, near Greifswald, Germany. Each pipe string requires approximately 100 000 12-metre long pipe sections.

To meet the tough performance criteria, Nord Stream AG selected the Borcoat bimodal, a three layer HDPE system with increased fusion bonded epoxy (FBE) primer thickness. It provides the mechanical strength necessary for pressurisation to 220 bar and to resist external pressures at depths down to 110 metres.

The system comprises a first base layer

of fusion bonded epoxy (FBE) coating, then a layer of Borcoat ME0420, a maleic anhydride grafted polyethylene adhesive giving a strong bond to the FBE, followed

by Borcoat HE3450, a black bimodal HDPE. A ‘rough coat’ of Borealis’ RM7405, a black PE ground material grade, was applied to the topcoat while still hot. This rough surface enables a stronger bond to the 60-110mm concrete coating to increase the weight of each pipe to around 24 tons and ensure its stability when laid on the seabed. www.borouge.com www.nord-stream.com www.borealisgroup.com

Eurocopter delivers first A350 XWB passenger door EUROCOPTER is producing the carbon fibre composite passenger doors for the Airbus A350 XWB aircraft at its Donauwörth, Germany, facility.

The A350 XWB passenger doors are the first for a commercial aircraft to be made entirely of carbon fibre reinforced plastic (CFRP).

The development and manufacture of aircraft components is another mainstay of Eurocopter’s activities in Germany, which complements our helicopter production. The A350 XWB’s door systems demonstrate our innovative strength and international competitiveness in the field of carbon fibre technology.

Series production is handled at Eurocopter’s Donauwörth site in a new building designed to meet the exacting requirements of automated production methods

and quality control at high production rates.

Eurocopter currently has approximately 250 employees working on the A350 XWB passenger door programme’s design, development and production. Series production eventually will involve more than 400 employees.

Total value of the A350 XWB door systems to be provided by Eurocopter is nearly €1.5 billion, which includes the cargo doors subcontracted to partners in South Korea.

Five cargo doors already have been delivered. A total of seven door shipsets for the A350 XWB are slated for delivery in 2012 – each composed of four pairs of passenger doors, two cargo doors and one baggage door.

Every year, the Donauwörth site produces more than 4000 passenger and

High-tech products for green mobility CUSTOMISED polyamides and polyesters for sustainable mobility concepts and colorants for plastics were the focal points of Lanxess’ exhibition at INTERPLASTICA 2012 in Moscow.

Lightweight nylon composite sheets that can be used alone or together with metal sheet in plastic or metal composite designs (hybrid technology) could reduce component weight by another 10% compared to aluminium sheet hybrid designs. Lanxess develops together with its partners in the automotive industry new applications for high-tech plastics. Nylon composite sheet hybrid technology is ideal for automotive light weighting. In many cases in terms of cost-benefit aspects it provides an alternative to thermosetting plastics, which are reinforced with continuous carbon fibres. Components that Lanxess considers possible to produce directly using polyamide 6 in nylon composite sheet hybrid technology include lightweight front ends, car seats, seat cross-members, airbag housings and brake pedals.

www.lanxess.com 96

The A350 XWB passenger doors are the first for a commercial aircraft to be made entirely of carbon fibre reinforced plastic (CFRP)

cargo doors for various aircraft types in the Airbus product line. www.eurocopter.com

MATERIALS

New high stiffness PP supports environmental goals Productivity, environmental advantages for converters within a one-material solution converters within a one material solution, including: between 10-20% reduction in cycle time with shorter cooling times possibilities for downgauging and weight reduction energy and cost savings through low temperature processing and low injection pressures as well as faster cycles reduced carbon footprint from less energy consumption good stacking and drop performance for finished pails of all sizes

www.borealisgroup.com

In addition to large containers and pails for food, paint, DIY and other consumables, Bormod BH381MO is suitable for other packaging applications where high stiffness with good impact and good flow is required, e.g. thin walled packaging, houseware and transport packaging.

(PHOTO: WOLF PLASTICS)

BOREALIS has launched a unique, high stiffness polypropylene (PP) grade Bormod™ BH381MO to support manufacturers of industrial pails in meeting their increasing sustainability and product quality goals.

New heterophasic copolymer Bormod BH381MO uses Borealis Nucleation Technology (BNT) to achieve a one-of-a-kind balance of excellent stiffness, flow and impact. The PP grade has a melt flow rate (MFR) of 35 that behaves like traditional MFR 45 grades. At the same time its stiffness level (tensile modulus) of 1700 MPa is more than 150 MPa higher than standard MFR 30 grades, yet with the same impact performance of softer grades. The higher stiffness performance is maintained in high temperature environments.

The combination of characteristics allows for lower processing temperatures and lower injection pressure including the ability to fill more complex parts. It also supports easier de-moulding. This creates a spectrum of productivity and associated environmental related advantages for

AUGUST / SEPTEMBER 2012 97

New liquid colour technology for polyolefin blow moulding Liquid vehicle technology ideal for monolayer extrusion blow moulding NEW LIQUID vehicle technology (LVT) developed by Clariant Masterbatches appears to eliminate many of the problems that have prevented wider use of liquid colour and additive concentrates in extrusion blow moulding of polyolefins (high and low-density polyethylene and polypropylene).

Initial testing in monolayer containers shows that these highly compatible systems allow for higher pigment loadings and lower usage rates, while practically eliminating past challenges related to screw slippage. Improved resin compatibility results in stronger weld lines in the finished container as evidenced by scores in standard burst and compression-loading tests.

“Extrusion blow moulders and brand owners in the personal care and household products markets often find liquid masterbatches to be an attractive alternative to solid concentrates,” said Raymond Sloan, head of liquid colour, Clariant Masterbatches North America. “However, until now, use of liquid colour has been limited in blow moulding of polyolefin resins because many liquid based carrier systems (including mineral oil) would not incorporate well

with the resins. It was pigment friendly, but not resin friendly.”

The new Clariant masterbatches use a liquid vehicle system that incorporates suspension aids and binders to allow for higher pigment loadings and (in most cases) lower usage rates. Additional components enhance flow and make for dramatically faster colour changes.

Benefits include: Improved weld-line strength. Previous carriers had a tendency to rapidly bloom to the surface of extrusion blow moulded containers, interfering with seam rewelding.

The new Clariant liquid products appear to actually assist in the formation of a strong seam.

Better processing characteristics. The new Clariant liquid colours have a positive effect on material

flow in the extruder. Reduced screw slippage leads to improved mixing and more complete dispersion and less streaking. It also results in processing temperatures as much as 17°C lower and, therefore, less cooling is required.

Faster colour changes and greater productivity. The Clariant LVT products tend not to adhere to metal surfaces and, in fact, can act as a cleansing agent, removing deposits left behind by other colorants. Colour changes that might typically take several hours with solid pellet colorants can now be completed in just minutes with the new liquid colours from Clariant. www.clariant.co.za

Moulding future growth MOULD Release agents are essential products in the design and manufacture of any pre-shaped part – whether it be rubber, plastic, thermoplastic or an advanced composite.

Mould release agents form a coating on the mould, allowing the part being moulded to be released quickly and easily. Conventional mould release products have no chemical interaction to the mould surface and release by transferring some of the mould release product to the part surface. Additionally it requires frequent re-application, typically after every release. These release agents are referred to as sacrificial mould release agents.

Semi-permanent mould release agents differ from conventional www.loctite.co.za

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sacrificial mould release agents in that they allow multiple releases with a high quality finish, reliable release performance, low mould build-up with low or no transfer of the release agent onto the moulded part.

Henkel produces a range of semipermanent mould release products for the advanced composites, polyester and rubber industries under the Frekote brand name that offer multiple releases per application.

Within each of these classifications there are products to meet a wide variety

of application needs such as gloss finish levels, slip properties, temperature considerations and material usage. In addition, the products can be wiped on or sprayed on and both water and solvent-based formulae are available.

Henkel produces a range of semipermanent mould release products for the advanced composites, polyester and rubber industries under the Frekote brand

MATERIALS

Like a second skin!

ImpranilÂŽ coating opens door to innovations in adidas running shoes and sportswear ATHLETES throughout the world spent a great deal of time preparing for this yearâ&#x20AC;&#x2122;s Olympic Games in London. More than just efďŹ cient technique is required for a runner to achieve peak performance; natural motion and a comfortable ďŹ t are also important.

The new â&#x20AC;&#x2DC;adipureâ&#x20AC;&#x2122; line of training shoes from adidas supports natural running through a rolling motion over the metatarsus and forefoot. The shoes also satisfy runnersâ&#x20AC;&#x2122; other requirements, thanks not least to the upper material of the shoe, which envelops the foot seamlessly like a second skin. It owes its unique properties to a textile coating based on a polyurethane dispersion from Bayer MaterialScienceâ&#x20AC;&#x2122;s ImpranilÂŽ range.

The textile coating is noted in particular for its high resilience. It is vital for the runner that it is applied precisely to the upper material at the points where the foot needs support. There, the coated material braces the foot but also offers it enough freedom to stretch. As a result, it makes a decisive contribution to the runnerâ&#x20AC;&#x2122;s perfect natural running experience.

When it came to designing the coating, the adidas experts drew on the results of measurements obtained with the help of sensors placed on runnersâ&#x20AC;&#x2122; bare feet.

The application of the coating provided the designers with almost unlimited design scope. Furthermore, the process protects the synthetic upper because the shoe is not subjected to any thermal stress during production.

ImpranilÂŽ dispersions are waterborne and completely cosolvent-free. Textile coatings formulated with them retain their excellent properties after machine washing and drying. Stress-strain tests provide impressive proof of their high resilience.

The new â&#x20AC;&#x2DC;adipureâ&#x20AC;&#x2122; line of training shoes from adidas owes its unique properties to a textile coating based on a polyurethane dispersion from Bayer MaterialScienceâ&#x20AC;&#x2122;s ImpranilÂŽ range

www.adidas.com www.materialscience.bayer.com AUGUST / SEPTEMBER 2012 99

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TECHNICAL

Biogas from spaghetti?

Evonik membranes upgrade biogas BIOGAS is an eco-friendly energy source that is becoming increasingly important in today‘s energy supply. But an extensive upgrading and purification process is required before biogas is fed into the natural gas grid. New and highly selective polymer membranes from Evonik convert raw biogas simply and efficiently into highly pure biomethane.

This increases yield and conserves valuable resources.

According to the Renewables Global Status Report (GSR) 2011, renewable

energies today account for about 16% of global energy consumption; by the year 2050, this figure could rise to more than 50%.

Biogas is produced by fermentation of biomass, an organic substance consisting of, for example, plants, liquid manure, or effluent sludge. But in addition to the methane energy source, raw biogas also contains carbon dioxide (CO2) and other trace gases. Because CO2 is not combustible, it lowers the calorific value of the gas and must therefore be separated out.

The common separation methods such as pressurized water scrubbing, pressure swing adsorption, and amine scrubbing have considerable disadvantages: They need comparatively large amounts of energy as well as auxiliary materials and chemicals. Wastes and wastewater are generated that must be treated and disposed of. Further, the biogas after upgrading is usually at low pressure. Before it is fed into a medium-pressure grid, it needs to be compressed to 15-20 bar by, for example, an additional compressor.

Biogas is produced by fermentation of biomass, an organic substance consisting of plants, liquid manure, or effluent sludge.

It looks like a bunch of spaghetti strands or a paintbrush, but is in fact a bundle of highly selective polyimide hollow fibres in Evonik’s new Sepuran membrane module

Conventional upgrading plants are therefore usually cost effective only for raw biogas quantities significantly in excess of 500 standard cubic meters per hour (Nm³/h). This usually makes them unsuitable for decentralized energy supply with a large number of relatively small plants.

Evonik Industries has developed a technology for cost- and energy-efficient separation of CO2. What appears at first sight to be a bunch of spaghetti strands or a paint brush is in fact a bundle of highly selective membranes made up of multiple cylindrical polyimide hollow fibres. These are used in the new hollow fibre membrane modules of Sepuran Green.

Highly selective membranes Polyimides are high performance polymers with high pressure and temperature resistance. Sepuran relies on a specially optimized form of Evonik‘s proven and tested polyimide family. The membranes have consistently high selectivity and are particularly suitable for separation of CO2 and methane.

How does the membrane work?

Gas molecules are different sizes and have different solubility in polymers. The biogas to be cleaned is introduced under high pressure at one end of the membrane. The CO2 molecules are smaller than the methane molecules and also

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more soluble in polymers. As a result, they pass through the micropores of the membrane much faster and are separated from the methane.

CO2, water vapour and traces of ammonia and hydrogen sulphide are drawn off at the low-pressure side (from the lateral opening depicted in the diagram), while the methane collects at the other end of the membrane, the high-pressure

side. The methane-rich gas is directly drawn off at the high-pressure side and needs no further compression for feeding into the grid. This saves the costs of an additional compressor. Further, the biomethane produced in this way can be used even by small plants and therefore allows decentralized supply of energy.

In a test plant in Neukirchen an der Vöckla (Austria), Evonik‘s experts have

been putting the production modules through their paces since early 2011.

Their experience so far is that the new Sepuran Green membrane modules are a robust and simple tool for gas purification. The methane of the raw gas can be cleaned to a purity higher than 99%. www.corporate.evonik.com

Biogas is produced by microbial fermentation of sustainable raw materials like corn, or from effluent sludge or liquid manure. Following separation of various minor components like water vapour, hydrogen sulphide, and particularly CO2, the biogas can then be used in the gas grid, in combined heat and power plants, and at filling stations

AUGUST / SEPTEMBER 2012 101

Design in 3D, Analyze in 3D

Integrated d with CAD systems: SOLID EDGE - NX - Creo - SolidWorks

WORLD NEWS

Car part weights could be cut in half LEADING automotive plastics component supplier, Monaco-based Mecaplast, believes it can cut the weight of interior and exterior trim parts by between 30 and 50% by using a newly patented injection moulding processing technology in combination with novel polypropylene compounds.

Mecaplast has numerous production facilities across France as well as in Europe, Turkey, Brazil, Mexico, China and India, is about to embark on a French governmentsponsored project called Plume (French for feather) to industrialize the process, which relies on a combination of moving mould cores, a chemical blowing agent, and lightweight reinforcing fillers. The project starts in September, and will run for two years. It will have a total budget of €2.4 million.

The project will also involve the participation of several other French companies: compound producer Sumika Polymer Compounds (a Sumitomo Chemical Group

company) based in Saint-Martin de Crau; mould-maker Cero, in Nantes; polymer science research laboratory IMP at the University of Saint-Etienne; and Sophia Antipolisbased Cemef, a research laboratory from Mines ParisTech, associated with CNRS, with expertise in process simulation.

“Incorporation of parts made by the Plume process could lead to a total vehicle weight reduction of between 5 and 7kg,” said Elsa Germain, research and innovation engineer at Mecaplast. “This will have an important knock-on effect on fuel consumption, with resulting carbon dioxide emissions falling by around 0.5-0.7g/km.”

The process is similar to one already used in Japan for production of parts used by such automotive companies as Honda and Toyota. However, that process has some limitations, especially in terms of surface finish, since the parts are made with talc-filled polypropylene (PP). The Plume

process will use newly-developed compounds that contain little or no talc.

Instead, they incorporate new reinforcing fillers that not only yield improved surface quality but also help reduce part weight by as much as 7%, without loss of mechanical properties. The new compounds, which are based on PP impact copolymer and are being developed exclusively for Mecaplast, also have very good flow properties. Melt flow index is over 50 g/10 min. This is critical for the success of the Plume process.

The Plume process In the Plume process, material is injected into a mould with moving walls that are initially in the forward position. Once all the material has been injected, and the skins of the part have solidified, the walls retract. This lowers the pressure in the mould cavity, and chemical blowing agent, until now dissolved in the melt, comes out of solution in the areas of the part that are still fluid to create a cellular structure that fills the newly created space.

The foaming process on its own (disregarding compound formulation) enables a weight reduction in the part of at least 30%, compared to a conventional solid moulding.

Cemef will look at melt rheology and its effects on the process and it will also carry out analysis of the microstructures created by the chemical foaming. IMP-UJM will study the mechanical behaviour of parts made under various conditions.

Mecaplast plans to trial the process on two components, a tailgate interior trim and exterior beltline mouldings. The beltline mouldings will be produced in two versions, one with a grained surface that will require no painting and another that will be paintable.

www.mecaplast.com Structure of a foamed part (Photo Mecaplast, MPPR001)

AROUND THE WORLD BASF TO BUILD BUTADIENE EXTRACTION PLANT IN ANTWERP BASF plans to build a butadiene extraction plant at its Verbund site in Antwerp, Belgium.

The plant will have an annual production capacity of 155,000 metric tons and is scheduled to start up during 2014. Butadiene is a simple conjugated diene with the formula C4H6. It is an important industrial chemical used as a monomer in the production of synthetic rubber.

The decision has been made in light of the 102

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increasingly tight supplies of butadiene on global markets. In recent years, the volumes of butadiene available on the market have declined sharply. At the same time, demand from the tire industry and other industries has been rising. This has led to a considerable increase in prices. www.basf.com

HANWHA AZDEL INVESTS $20 MILLION IN NEW PLANT FOR LWRT COMPOSITES THE Hanwha Azdel division of Hanwha L&C Co., Ltd. of Seoul, South Korea will expand its SuperLite® lightweight reinforced thermoplastic (LWRT) composite product line with a $20-million investment that will be used to construct a new plant in Bugang,

South Korea. Scheduled to come on stream in 2014, the facility will be located inside Hanwha L&C’s existing Bugang Plant #2, home to the company’s existing glass-mat thermoplastic (GMT) composite production plant. Both facilities will service global automotive, heavy-truck, recreational-vehicle, and industrial customers with production operations in Asia. www.azdel.com

BASF INVESTS $2.7 MILLION IN FRX POLYMERS BASF Venture Capital has invested $2.7 million in the advanced materials company FRX Polymers, Inc. The investment is part of a series B financing round of $26.7 mil-

Big Amcor on-site plant at Pepsi in USA

Amcor Rigid Plastics’ new in-line operation in the USA is expected to produce approximately 650 million hot fillable PET bottles annually

www.amcor.com

AMCOR Rigid Plastics, one of the world’s leading producers of rigid plastic packaging, opened its new on-site bottle manufacturing operation at PepsiCo’s Gatorade production facility in Mountain Top, Pennsylvania, USA, in June. The new in-line operation is expected to produce approximately 650 million hot fillable PET bottles annually.

Previously, the Mountain Top Gatorade facility had purchased hotfill PET containers from merchant suppliers. On-site bottle manufacturing is a highly efficient and sustainable business model for beverage makers, according to Larry Weber, general manager of Amcor Rigid Plastics’ North America. Beverage companies like PepsiCo can gain major sustainability benefits and eliminate expenses associated with shipping, including unnecessary handling, secondary packaging and freight costs. Amcor has strong expertise in running on-site manufacturing operations with seven similar hot fill facilities located at beverage filling plants throughout the USA. Amcor received strong backing and financial support from state and local agencies including approximately $100,000 in grants for site development and employee training.

Plastic fantastic Modern lightbox – Decorating the interior of our habitat has been a creative activity of ours ever since we’ve started living in caves.

Now, interior design has become not only a profitable business, but also a form of art.

Using roto-moulded plastic, this seamless cube has many uses. A stool, an end table or nightstand, or an attractive lamp, the Lightbox can add a cubical glow to any space big enough for an 45cm cube. The product supports up to 90kg.

Recycling at NPE2012 collects twice as much FOR five days in April, the NPE2012 international plastics exposition transformed the Orange County Convention Center (OCCC) in Orlando, Florida into a virtual manufacturing city, generating many tons of industrial scrap in addition to packaging and other postconsumer waste. None of it, however, ended up in landfills, according to the OCCC and SPI: The Plastics Industry Trade Association, which produces the triennial NPE. Final figures provided to SPI by Maine Plastics, Inc., the official recycler for NPE2012, indicate that the production scrap generated by machinery operated on the show floor by 56 exhibitors participating in the ‘NPE Recycles’ programme amounted to 118 tons. This was more than double the 57 ton total for NPE2009, where 45 exhibitors participated.

www.plasticsindustry.org

lion. FRX Polymers develops and produces innovative, non-halogen flame-retardant polymers. www.basf.co.

AZELIS SELLS THERMOPLASTICS BUSINESS TO GAZECHIM CHEMICALS distributor Azelis is selling its thermoplastics business to Gazechim Plastics as part of plans to focus on specialty chemicals and ingredients. Gazechim is based in France and has annual turnover of €340m.

Azelis still has the materials pigments and additives business which supports the polyvinyl chloride, and polyurethane businesses, as well as other plastic polymer producers,

compounders and master batches. The project only concerned Azelis activities in Europe and the company will continue with its thermoplastic polymer business in its Indian and Chinese operations. In a statement, Gazechim says the deal will allow it to spread its plastics capabilities out of France and across Europe.

commissioned and the first test runs have already been finalized. Several batches of high quality Puralact® lactides have been produced and actual deliveries to customers started early 2012. www.purac.com

HUSKY SELLS INJECTOPLAST TO ALPLA

HUSKY Injection Moulding Systems has completed the sale of Injectoplast, the former closure injection moulding operation of KTW, to Alpla Holding GmbH (A-6971 Hard, AusPURAC has successfully completed the construction of its new 75 000 ton/year lactide tria). The sale agreement was announced January 24, 2012. Injectoplast was a division plant in Thailand. The construction of this of KTW, a closure mould maker Husky €45 million state-of-the-art plant started in March 2010. At the moment the plant is being acquired in early 2011. www.husky.ca

PURAC’S 75 000 TON LACTIDE PLANT IN THAILAND

AUGUST / SEPTEMBER 2012 103

WORLD NEWS

Octal PET system cuts cost of scrap THE new direct-to-sheet process (DPET™) from OCTAL eliminates five energy-intensive stages of the conventional sheet production process (pelletizer, SSP, compactor, dryer and extruder). In the new system the PET melt arrives at the calendar stack heated to the proper temperature and does not have to be dried and re-melted from the granular form. The system also offers absolute traceability as the resin is constrained to one source providing the origin of the resin.

The uniformity of the sheet has allowed

OCTAL to design a winder that constructs precision rolls with unnoticeable weave and near perfect formation. Thermoformers benefit from this advantage by being able to minimize side trim. DPET is manufactured to a typical caliper variation of +/- 1%, allowing thermoformers to specify a thinner sheet and still achieve package performance in finished trays.

DPET can be run at a 10% faster cycle time and at temperatures up to 5 degrees lower than conventional APET, while still retaining clarity and gloss.

THE new unique direct-to-sheet process (DPET™) from OCTAL

www.octal.com

PTi sells sheet line to Turkey ASERPET of Turkey, a PET recycler and manufacturer of PET sheet roll stock, has purchased a high-performance sheet extrusion line from Processing Technologies International (PTi) of the USA. Aserpet, a recycler of PET flake for the packaging industry, purchased its first sheet extrusion line to support its entrance into the packaging industries. The PTi coex line, which runs 750kg/ hr of PET, also includes a roll stand, winder, and stacker. The machine is up and running at the Aserpet facility in Gaziantep.

Aser Tekstil was established in 1971 for the purpose of manufacturing kilim yarn. It started to manufacture jute yarn in 1985 and ‘fancy’ yarn in 1996. It started to make PET flake recovery in March 2007 and built the Aserpet facilities in Gaziantep on 7500m² closed and 8000m² open area to handle its current capacity of 520 ton/month. www.aserpet.com.tr

www.ptiextruders.com

Mondi buys Nordenia group NORDENIA International AG, a multinational manufacturer of consumer packaging solutions and hygiene components, was sold to Mondi Group in July for €655 million, subject to the approval of competition authorities and customary closing conditions. The completion of the acquisition is expected in the fourth quarter of 2012.

It is planned that the existing Nordenia

management team will lead the combined consumer packaging business unit from its current headquarters in Greven, Germany.

Nordenia group sales increased by 9.9% in 2011 to € 881.0 million, the sales volumes increased year on year by 1.4% to 244 670 tons. The adjusted EBITDA (adjusted earnings before interest, taxes, depreciation, amortization, and other extraordinary expenses and income)

amounted to € 101.1 million.

For the year ended 31 December 2011, Mondi Group’s consumer packaging business generated revenues of €281 million, EBITDA of €30 million and return on capital employed of 17%. www.nordenia.com www.mondigroup.com

Nordenia USA opens BIG plant NORDENIA USA, a specialist manufacturer of high-quality films, took occupation of its new 17,000m² premises in Hubble Creek, Jackson, Missouri, on 27 June. The plant houses extrusion, printing, bagmaking and ancillary equipment in a €3.5 million (the building is leased). Nordenia USA, in operation since 1989, is part of the Nordenia group is based in Greven, Germany “The new plant will enable us to increase our flexibility with regard to our customers and will strengthen our competitive position,” said Ralph Landwehr, CEO of Nordenia International AG. Its most important products are elastic diaper components, for which the Nordenia is a global market leader, FlexZiBox® bags with four sealed edges, NorDiBag flexible packaging, and stand-up pouches.

www.nordenia.com

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LETTERS

Training raises complicated set of challenges in SA Response to â&#x20AC;&#x2DC;Letter to the Editorâ&#x20AC;&#x2122; by Dave Ransom in June/July 2012 issue: I most sincerely thank Dave Ransom for his response. He has helped to point out the complicated situation with trying to train the members of an industry in South Africa.

The whole point of the creation of the initiative to link education and training to BBBEE is to create funding from which to provide the best and most appropriate interventions that will lead to a better educated workforce in the rubber industry.

The proposal is based on a holistic view of the industry and in no way meant to denigrate the efforts made by individual private agencies to provide a training service.

We would not even be talking about this issue if the current service providers had the support and the capacity to educate and train the substantial numbers that are currently employed in the Industry on a long term basis. I am the ďŹ rst to acknowledge the positive efforts made by the

two private companies mentioned and, when still in business, I made use of their services.

However, we are not talking about rubber skills training only. We need to be able provide the resources to educate and train all of the members of a substantial industry from shop ďŹ&#x201A;oor to senior management, if we are to survive and prosper as a deďŹ ned industry. National education, whether we like it or not, is based on national structures. They are the best we have and are the legal basis for the development of education and training courses that will lead to qualiďŹ cations that are portable and recognised within general industry in South Africa. This is the rule for national qualiďŹ cations that qualify for substantial SETA grants and funding.

This effort by the IOMÂł, as the only professional body in the industry and trying to make a difference, is to create the facili-

ties for members of the rubber industry to educate and train their staff. The services of the private companies mentioned would be expected to be an integral part of this process. The scope of the vision, however, is to provide opportunities for education and training that are far greater than those currently being offered.

In my opinion, a broader view has to be taken if we are to retain anything of a viable and progressive local industrial rubber industry in the face of the competition coming from the developing world. Just take a look at what was 20 years ago and what is now. We can no longer compete in mass markets and so specialised niche markets are the only opportunity left. The success criteria in a niche market are service and expertise. Have we got them?

Dave Duncan AUGUST / SEPTEMBER 2012 105

Perspex4 INSIST (' #- 2 ' & Last year we became bigger when XPS joined our family, and, as you may have heard, we are NOW in a position to offer a vastly improved quality product right now! Therefore we now offer our customers the trusted Perspex brand, made to global standards and access to global technologies and innovations. "#, !#/ , (-" ' -" ())(+-.'#-2 -( ( + -(- %%2 .'#*. ,$ - ( !(( , -( -" & +$ - #' -" - -" (& #' ( +#'! .++ '-%2 #' (+)(+ - , ,- +2%# +,) 1

' ," -#'! , 0 %% , .%-#0 %% (%2 + (' - " , )+( . -, + ., #' 0# + '! ( ))%# -#(', #' %. #'! ,#!' ! )+#'-#'! ) $ !#'! + "#- -.+ ' ,#!' -( ' & 0 (-" (&) '# , () + - .' + ," + + ,(.+ , , % , ' &#'#,-+ -#(' )% - (+& , (' -" ,2' +!# , -" - 1#,- -0 ' -" )+( . - ))%# -#(' & +$ - , !& '-, ' -" + (+ ," + (' /#,#(' 0"# " #, -( -" ,.))%# + ( "(# (+ -" #+ ,) #3 ,$ - ( !(( , #' -" +#!# ," -#'! & +$ - (-" ' -#(' %%2 ' #'- +' -#(' %%2

+,) 14 INSIST on it by name. q 1 )-#(' % %#!"- -+ ',&#,,#(' 0#-" '( #'" + '- ! (%(.+ q 1 %% '- + ,#,- ' -( (.- ((+ 0 -" +#'! q #!" !%(,, " + ,.+ q (( -" +&( (+& #%#-2 q ,2 -( % ' q - #%#-2

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We now also supply Polygal Multiwall Polycarbonate!

USEFUL INFO ON THE INTERNET

‘How valuable is your time?’

New on-line modelling tool simplifies tie layer selection

This meat packaging example illustrates the complexity of today’s packaging and the role tie-layers play in bonding dissimilar materials

THE second in a series of online predictive modelling tools from DuPont Packaging promises to simplify tie-layer material selection, a critical step in multilayer packaging design.

“Selecting the right coextrudable adhesive ensures dissimilar polymers bond – and stay bonded from manufacturing through consumer use,” said Barry Morris, PhD, DuPont Packaging technology fellow.

“In today’s world, designers have hundreds of options and their performance varies based on the packaging structure’s manufacturing process, the contents of the packaging, the environment that the packaging is exposed to – selecting the right adhesive is critical; it doesn’t have to be frustrating.”

DuPont, which supplies the world’s broadest range of specialized co-extrudable adhesive resins, offers the DuPont Tie Resin

Selector as the first step in selecting the best resin. Users start by identifying two materials to be joined together and the Selector provides a short list of recommended grades of DuPont tie resins grouped by type of extrusion process. The Selector includes links to data sheets for recommended grades, to other relevant literature and to a customer service contact for sample ordering and inquiries.

Its database includes more than 40 grades of DuPont™ Bynel® coextrudable adhesives plus several grades of DuPont Elvax® EVA copolymer and DuPont Nucrel® acid copolymers.

“Identifying the right candidates early in the design process can help avoid expensive, iterative trials and, of course, costly errors late in the process,” said Morris. “It’s also a global tool with answers tailored to special needs in each region.” The Tie Resin Selector is the latest addition to a suite of tools that DuPont uses with its customers to help optimize packaging structures and processes. Two of these are now available on the web; the other is the DuPont™ SAVE tool for calculating total packaging cost using alternative sealants.

“DuPont computer modeling and simulation tools save development costs and time by helping our customers identify cost-effective material combinations and processes,” said Mike Hiteshew, DuPont Packaging global eMarketing leader. “Stay tuned for more web-based tools in the future.”

Drawing from an extensive mix of adhesives, sealants, modifiers; barrier and peelable-lidding resins, DuPont Packaging & Industrial Polymers works with customers around the world on packaging initiatives that help protect the product, environment, improve shelf appeal, convenience and re-

FREE ACCESS BUYERS GUIDE FOR TECHNICAL TEXTILES INTERNATIONAL Newsletters Ltd has released a new ‘International Buyers Guide for the Technical Textiles Industry,’ available online.

Freely available to users, the guide lists more than 1000 suppliers, manufacturers and service companies and research institutes from around the world, classified by activity and country in a fully searchable and interactive format. It will prove an invaluable source of information for potential 106

AUGUST / SEPTEMBER 2012

customers searching for new partners, suppliers, manufacturers, end-users, or support services.

All entries include company name, contact details and activity. Companies can also choose to highlight their entries with logo, company description and live website links. www.intnews.com/TTIBuyersGuide

duce cost in the food, cosmetics, medical products and other consumer goods and industrial packaging industries.

DuPont (NYSE: DD) has been bringing world-class science and engineering to the global marketplace in the form of innovative products, materials, and services since 1802. The company believes that by collaborating with customers, governments, NGOs, and thought leaders we can help find solutions to such global challenges as providing enough healthy food for people everywhere, decreasing dependence on fossil fuels, and protecting life and the environment. For additional information about DuPont and its commitment to inclusive innovation, please visit www.dupont.com

PLASTICS MARKETPLACE IF YOU’RE looking for a one-stop shop for all your plastic scrap needs, then take a look at The Plastic Marketplace. Here you can contact both buyers and sellers immediately. You can also make contact with other members via live chat, skype, instant message, email and phone, eliminating the chance of missing out on material you locate.

Theplasticmarketplace.com also has plans to host a virtual tradeshow each quarter. The tradeshow will provide you access to hundreds of customers and vendors without having to leave your office. You can converse with exhibitors (real-time), display your company’s products and services and attend conferences and seminars without any travel expense at all. You will be able to invite your customers and enjoy all the benefits of a tradeshow at a fraction of the cost. www.theplasticsmarketplace.com

BOOKS

Protecting plastics & rubber THE worldwide market for stabilisers and other additives which protect plastics from degradation when exposed to heat and light will achieve revenues of almost US$4.8 billion by 2018 forecasts Oliver Kutsch, CEO of Ceresana Research. According to the new study of Ceresana, the Asia-Pacific accounts for about half of all demand, followed

by Western Europe and North America.

Heat stabilisers are mainly needed for construction materials made of PVC: More than 85% of all stabilizers sold during 2010 were used in profiles, pipes, and cable jackets.

The market for light stabilizers is growing worldwide. Particularly HALS (Hindered Amine Light Stabilizers), used in products made of polypropylene or polyethylene, will see great increases in demand. Ceresana Research anticipates that the Asia-Pacific region will continue to strongly influence the stabilizer market over the next years. In addition, South America, Eastern Europe, and the Middle East register above-average growth rates of 3.5% to 4.7%.

The study summarizes the most important facts on the different types of heat and light stabilizers on 567 pages. The global market is analysed in detail, above all the 17 countries with the largest demand. Most important application areas, such as pipes, films, and elastomers, are examined one by one. www.ceresana.com

Biotechnology in biopolymers THIS comprehensive book provides up-todate information on the developments in the field of biopolymers.

Close attention has been paid to include all the important aspects that are necessary to understand the field.

The book introduces the reader with the progress in the field, followed by outlining its applications in different areas.

Different methods and techniques of synthesis and characterization are detailed as individual chapters. Various mode and mechanism of degradation of materials will be discussed. There is a dedicated chapter on industrially available biopolymers and their applications as well as a chapter detailing the ongoing research, current trends and future challenges.

Unlike other books, this book consists of information that is useful for students who are interested in biotech and polymer research. Each chapter will explain the science and technology from the inception to advance state of the art available to date. This book will also be useful for the researcher involved in the high-tech research as it will provide them the up-to-date information available in this field. www.polymer-books.com

Asia’s middle class driving BOPP film markets THE BOPP film industry continued to show robust growth during 2011 with demand advancing by 5.5% compared with 2010 to top 6 million tons for the first time, according to the latest report on the global BOPP film market from AMI Consulting.

Demand growth was slightly down on 2010 which had been the bounce back year from the financial crisis for most markets around the world.

Global demand is increasingly being driven by developments in Asia, particularly in China, India and Indonesia. With over 60% of BOPP usage occurring in food packaging, it is the growth in demand in these countries for an ever-widening variety of packaged foods sold through supermarket outlets that is one of the main drivers for this material. With large, youthful and growing populations, increased urbanisation and rising incomes it is the developing markets of Asia that will continue to underpin growth in BOPP film demand.

AMI’s analysis shows that China alone now accounts for 40% of global production

and demand and on its own accounted for 2 percentage points of the global growth achieved in 2011. It accounted for 95% of all new capacity installed in 2011.

Although production has and will continue to be primarily to serve the domestic market, the volume of output now is such

that even modest export volumes have the potential to disrupt other markets. Chinese exports, which AMI estimated were 6% of production in 2011, are largely targeted at neighbouring Asian countries, but material can turn up in any part of the world from time to time.

AMI believes the BOPP film market has the potential to continue growing at a strong rate of 6-7%/year over the next five years. This would add another 2.3 million tons of demand. As was seen in 2011 the strongest growth is likely to continue to be in India, driven by the development of the organized retail sector opening up to foreign investment; China, driven by government initiatives to increase domestic consumption and raise living standards of its rural poor; and the Middle East and Africa, driven by general economic growth within this resource rich region.

BOPP films - the global market is a detailed market report from AMI Consulting. www.amiplastics.com AUGUST / SEPTEMBER 2012

107

Production efďŹ ciency with Arburg at FAKUMA THE theme of lightweight construction, which is growing in importance, is the focus of the Arburg display at the FAKUMA show in Friedrichshafen, Germany, from 16â&#x20AC;&#x201C;20 October.

One exhibit is of the new â&#x20AC;&#x2DC;long-ďŹ bre direct injection mouldingâ&#x20AC;&#x2122; process developed with German Plastics Center SKZ in WĂźrzburg. The process allows inline feeding and enables longer ďŹ bres than ever before to be processed, so that lightweight injection moulded parts with thin walls and high strength can be produced.

Particle-foam Composite Injection Moulding (PCIM) is a joint project with Krallmann and Ruch Novaplast in which a foamed part is combined with plastic for the ďŹ rst time. The two components are bonded, so that there is no need for subsequent assembly steps and a ďŹ nished part is produced in a single step. This production of composite components made from particle foam and injection moulded plastic opens up a whole ďŹ eld of new options for the electric mobility, lightweight construction and insulation sectors. www.arburg.com

Production efďŹ ciency through process integration: Arburg is presenting a production cell with inline printing for the manufacture of individually decorated plastic parts at Fakuma in October

TRADE between South Africa and Thailand has increased exponetially over the last few years, and some of the Thai manufacturers took advantage of that momentum by participating in the Thailand Trade Show at the Cape Town International Convention Centre in June.

Opportunities exist to cooperate with Thai manufacturers, to supply products not manufactured locally or to export to Thailand. www.tradeprojects.net

2012 EVENTS â&#x20AC;&#x2DC;HOW TO CONVINCE INVESTORS TO SUPPORT THE COMMERCIALIZATION OF YOUR PRODUCTSâ&#x20AC;&#x2122; A NOVEL competition is being held as part of the Global Polymer Innovation Expo (GPIE) conference/exposition to in Columbus, Ohio, USA, from 26-29 August: the â&#x20AC;&#x2DC;RAPid Impact 2012â&#x20AC;&#x2122; competition is aimed at teaching researchers the â&#x20AC;&#x2DC;art of crafting scientiďŹ c messages for lay peopleâ&#x20AC;&#x2122;. The event promotes the mentoring and development of students and post-doctoral scholars in the polymer ďŹ eld.

Polymer students are invited to team with a â&#x20AC;&#x2DC;principal investigatorâ&#x20AC;&#x2122; to enter RAPid Impact. Participating in RAPid Impact will â&#x20AC;&#x153;hone the skills necessary to communicate complicated topics to ďŹ nancial decision makers with the goal of convincing investors to support the commercialization of their productsâ&#x20AC;?.

GPIE features the six key areas of polymer growth 108

AUGUST / SEPTEMBER 2012

PHOTOS: TESSA Oâ&#x20AC;&#x2122;HARA

Thai show at CTICC

Ocean Plastic Intertrade www.rotoplanet.net

from the Ohio Polymer Strategy Councilâ&#x20AC;&#x2122;s 2011 Roadmap: s #ONDUCTIVE ELECTRONIC POLYMERS

s 0OLYMER NANOCOMPOSITES

s (IGH PERFORMANCE POLYMERS

s "IO BASED POLYMERS FEEDSTOCKS

s $EGRADABLE RECYCLABLE POLYMERS AND s $IRECT DIGITAL ADDITIVE MANUFACTURING For conference details and keynote speakers, visit www.GlobalPolymerInnovationEXPO.com.

SPE AUTOMOTIVE COMPOSITES CONFERENCE 4(% TH 30% !UTOMOTIVE #OMPOSITES #ONFERENCE %X hibition takes place from 11-13 September at the MSU Management Education Center in Troy, Michigan, USA. Now in its twelfth year, the SPE ACCE event has become the worldâ&#x20AC;&#x2122;s leading forum for automotive composites and draws exhibitors, speakers, and attendees from 15 countries on ďŹ ve continents. â&#x20AC;&#x153;With the global automotive industry growing again after several difďŹ cult years, and with a host of tough new

Pioneer Industrial Corporation www.pioneer-industrial.com

emissions and fuel-economy standards looming for the industry to meet, interest in lightweight materials like polymer composites is at an all-time high. Fortunately, the composites industry has a broad portfolio representing a wide range of cost, performance, and processing options from which to choose. â&#x20AC;&#x153;Whether automakers are working on low volume/ performance platforms, or high volume/economy platforms, they will ďŹ nd materials and process options that will meet their needs. And the best way to keep on top of the very latest technology innovations in this ďŹ eld is to ATTEND THE ANNUAL 30% !##% SHOW v SAID #REIG "OWLAND

the 2011 and 2012 SPE ACCE conference chair. www.4spe.org

PHOTOVOLTAIC MATERIAL PERFORMANCE IN ARIZONA SUN ARIZONA is regularly selected for weathering testing of photovoltaic materials and modules owing to its dry, sunny climate. It is also one of the optimum locations for solar energy farming. In view of this, the next AMI international conference on Plastics in Photovoltaics

BRICS forum at SAITEX and Industry (JCCI) in association with BRIC trade consulates and the Department of Trade and Industry convened a series of trade opportunity presentations and seminars aimed at opening dialogue between trade representatives from BRIC countries and African business visitors.

Each BRICS country was assigned four presentations aligned to ease of conducting business in that country, investment opportunities, export opportunities and import opportunities.

DIARY

THE vast, largely untapped potential for BRICS# intra-Africa trade received a boost through the newly-launched BRICS Africa Export Import Forum, which ran alongside SAITEX (the Southern African International Trade Exhibition) at Gallagher Convention Centre in Midrand in July.

The BRICS Africa Export Import Forum is the only event that is dedicated to showcasing the range of services and support available for BRICS trade into and around Africa trade.

In addition to the exhibition element, a number of co-located events designed to stimulate trade were staged. The Johannesburg Chamber of Commerce

# BRICS is an international organisation of leading emerging economies arising out of the inclusion of South Africa into the BRIC (Brazil, Russia, India, China) group in 2010.

www.exhibitionsafrica.com

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1. Jingdong Rubber of China, which has been manufacturing rubber sheeting and related products since 1985, exhibited at SAITEX www.jingdongrubber.com 2. Seen on the Lumoss Mouldings stand were Sally Anne Phora, Belinda Tverdon and Christopher Edgar www.lumoss.com

PHOTOS: LOWRIE SHARP

3. Cheri Scholtz of PETCO and Lisa Parkes, the PET organisation’s new commercial director, visited David Drew of the Boxmore stand www.boxmore.co.za 4. Evernu Plastics of Durban exhibited its range of domestic/home items at SAITEX www.evernu.co.za

2012 will be held on 19-20 September in Phoenix, AZ, USA. The event starts with a review from Professor Dauskardt of Stanford University on the challenges for plastics in photovoltaics, followed by Solaria describing research data from polymer aging studies. www. amiplastics.com

MEDIPLAS 2012 MEDIPLAS, to be held in Birmingham, UK, from 25-26 September, is a uniquely focused event for the highly specialised area of manufacturing plastic parts for the medical industry. The exhibition will cover all areas of the medical plastics supply chain.

It differentiates itself from general plastics shows, as it brings to the forefront aspects and considerations of medical device manufacturing that do not feature in production for other industries. It is also distinct from existing medical device events because it specialises in plastics – the new material of choice as biocompatible plastics and polymer compounds continue to replace metal and ceramics in the medical industry. www.mediplasuk.com

KENYA ELECTRONICS SHOW IN OCTOBER The 16th ITELEXPO Kenya International Trade Exhibition on IT, Electronics and Telecom will be held in Nairobi from 6-8 October. The event will present over 10,000 products, equipment and machinery from over 30 countries. The number of exhibitors and visitors in 2012 is expected to rise by at least 20% since an aggressive campaign has been launched. Trade visitors from all over East & Central African countries are being invited directly and in collaboration with several regional trade bodies in Kenya, Tanzania, Ethiopia, Uganda, Somalia, Mozambique and Congo. www.expogr.com

PETPOINT 2012 NürnbergMesse and Messe München GmbH teamed up for the first time at Brau Beviale for PETpoint 2011.

Following on from this successful premiere, PETpoint – the PET segment at drinktec, the World´s Leading Trade Fair for Beverage and Liquid Food Technology – will be putting in another appearance at Brau Beviale in 2012 from 12-13 November. www.drinktec.com/en/Home/PETpoint AUGUST / SEPTEMBER 2012

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Starlinger Recycling celebrates 25yrs STARLINGER recycling technology invited players throughout the value chain of the plastics industry to celebrate 25 years of Starlinger recycling equipment at an open house event at its premises in Austria in June. The event featured technical presentations and live test runs on plastics recycling lines at the factory in Weissenbach, Lower Austria.

Highlights included demonstrations of the recoSTAR PET 330 iV+ and recoSTAR universal system. The recoSTAR 330 is currently the biggest PET bottle-to-bottle recycling line of its kind in the world. The recoSTAR 165 VAC was shown reprocessing film, fibre and nonwoven scrap material.

www.starlinger.com

PLUMBDRAIN AFRICA: 15-18 August Nasrec, Expo Centre, Johannesburg: www.interbuild.co.za EUROMOLD BRASIL: 20-24 August: Joinville, Brazil: www.euromold.com INTERPLAST BRAZIL: 20-24 August: Joinville, Brazil: www.messebrasil.com.br GLOBAL POLYMER INNOVATION EXPO: 26-29 August Columbus, Ohio, USA: www.globalpolymerinnovationexpo.com PROPAK WEST AFRICA: 4-6 September Eko Hotel, Lagos, Nigeria: www.propakwestafrica.com SPE AUTOMOTIVE COMPOSITES CONF: 11-13 September Michigan, USA: www.4spe.org PLASTICS IN PHOTOVOLTAICS 2012: 19-20 September Arizona, USA: www.amiplastics.com TAIPEI PLAS 2012: 21-25 September Nangang Exhib Hall, Taipei: www.taipeiplas.com.tw MEDIPLAS: 25-26 September: NEC, Birmingham, UK: www.mediplasuk.com ARMO 2012 (ROTO MOULDING): 30 Sept-2 Oct Lyon, France: www.armo2012.com TIRE LABEL LEGISLATION & MARKETING: 3-4 October Le Meridian Hotel,Brussels Belgium: www.tllm-conference.com

With 350 exhibitors and more than 7 000 visitors at the last event in 2011, Composites Europe is one of the leading fairs for the sector

ETECH AFRICA EXPO: 1-5 October Int’l Conference Centre, Harare: arlene@africaexchange.co.zm

Automation & serial production a focus at

INDPLAS: 5-8 October: Calcutta, India: www.indplas.in ITELEXPO KENYA 2012: 6-8 October: Nairobi, Kenya: www.expogr.com

COMPOSITES EUROPE 2012

INT’L AVK CONFERENCE: 8-9 October: Düsseldorf, Germany: www.avk-tv.de WASTECON 2012: 8-12 October: ELICC, East London: www.wastecon.co.za BRITYREX INTERNATIONAL 2012: 9-11 October Manchester, UK: eci-international.com@mimimail4.com

DIARY

DUBAI PLAST PRO 2012: 15-17 October Raffles Hotel, Dubai, UAE: www.cvent.com AFRIMOLD 2012: 10-12 October Gallagher Conv Centre, Midrand: www.afrimold.co.za MULTILAYER PACKAGING FILMS 2012: 16-18 October Maritim Hotel, Cologne, Germany: www.amiplastics.com/Events FAKUMA 2012: 16-20 October Friedrichshafen Exhibition Centre, Germany: www.fakuma-messe.de POLYOLEFIN ADDITIVES 2012: 23-25 October Maritim Hotel, Cologne, Germany: www.amiplastics.com AGRICULTURAL FILM 2012: 6-8 November Madrid, Spain: www.amiplastics.com/Events DRINK TECHNOLOGY INDIA: 6-8 November Mumbai, India: www.drinktechnology-india.com PACKTECH INDIA: 6-8 November: Mumbai, India: www.packtech-india.com PETPOINT: 12-13 November Brau Beviale, Nürnberg, Germany: www.drinktec.com PETNOLOGY EUROPE 2012: 12-13 November Nuremberg, Germany: www.petnology.com COMPAMED: 14-16 November: Düsseldorf, Germany: www.compamed.de WIND TURBINE BLADE MANUFACTURE: 27-29 November Maritim Hotel, Cologne, Germany: www.amiplastics.com FIRE RESISTANCE IN PLASTICS: 27-29 November Fire Resistance Conference: www.amiplastics.com EUROMOLD 2012: 27-30 November: Frankfurt, Germany: www.euromold.com THIN WALL PACKAGING: 3-5 December Maritim Hotel, Cologne, Germany: www.amiplastics.com PVC FORMULATION 2013: 12-14 March Hilton Hotel, Düsseldorf, Germany: www.amiplastics.com PROPAK AFRICA 2013: 12-15 March Nasrec, Johannesburg: www.propakafrica.co.za GREEN POLYMER CHEMISTRY 2013: 19-21 March Maritim Hotel, Cologne, Germany: www.amiplastics.com/events 110

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CARBON fibre reinforced plastics (CFRP) will be a focus at this year’s Composites Europe trade show, with the competence networks of CFK Valley Stade and Carbon Composites eV (CCeV) taking part.

CFK Valley Stade will be exhibiting at the show on 9-11 October in Düsseldorf, Germany, with a joint stand of its own for the first time this year.

Three months before the start of the fair, organiser Reed Exhibitions Deutschland said practically all the big names in the European composites industry had already booked stands – from the five major CFRP producers to the leading specialists in technology and automation.

This year, the themes of automation and serial production of composites will be highlighted.

Now in its seventh year, Composites Europe 2012 is co-located with the Aluminum World Fair. More than 1300 exhibitors from more than 50 countries are expected at the combined event. Composites Europe 2012 will host 400 of these companies.

• AS IN PREVIOUS YEARS, THE INTERNATIONAL CONFERENCE OF THE AVK (FEDERATION OF REINFORCED PLASTICS), GERMANY, WILL AGAIN PRECEDE COMPOSITES EUROPE 2012. CONFERENCE TOPICS ON 8-9 OCTOBER WILL INCLUDE THE GLASS REINFORCED PLASTIC (GRP) AND CFRP MARKETS, CURRENT DEVELOPMENTS FOR SERIAL PRODUCTION, AND SOLUTIONS FOR JOINING, REPAIR AND SIMULATION. www.composites-europe.com

Intersolar Europe SABIC Innovative Plastics was a leading participant at the Intersolar Europe conference/exhibition in Munich in June, showcasing its growing portfolio of specialty thermoplastics designed to support major trends in solar applications. Highlighting the applications on display was the solar industry’s first polycarbonate building-integrated photovoltaic (BIPV) panels for roofing, cladding and glazing, which illustrates the company’s continuing commitment to advancing customer’s sustainable energy generation through more efficient solar power.

www.intersolar.de

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SPORTS

Solar Impulse, the innovative solarpowered airplane, is to attempt its longest flight, from Switzerland to Africa

Solar Impulse to attempt flight to Africa Longest flight planned for manned solar plane

www.materialscience.bayer.com

SOLAR Impulse, the innovative solarpowered airplane, is to attempt its longest flight, from Switzerland to Africa. The aircraft uses technical expertise, high-tech polymer materials and energy-saving lightweight materials from Bayer MaterialScience, an official partner to the visionary Swiss bid to fly night and day around the world without fuel.

The testing 48-hour journey of over 2 500 km, which will cross the Pyrenees and the Mediterranean and end in Morocco, follows successful test flights including Solar Impulse’s first international

flight, from Switzerland to France and Belgium, in 2011. The flight will be excellent training for the round-the-world trip planned for 2014.

Project originators Bertrand Piccard and André Borschberg will take turns to fly the aircraft, with a scheduled intermediate stopover near Madrid, Spain to change pilots.

The trip will coincide with the start of work in Morocco’s Ouarzazate region to construct the largest solar power plant ever built. The Moroccan Agency for Solar Energy (MASEN) is leading the implemen-

tation of the integrated Moroccan Solar Plan, which aims at developing a minimum power capacity of 2 000 MW by 2020.

Leverkusen-based company Bayer MaterialScience became an official partner of the Swiss Solar Impulse project in 2010. Since then, more than two dozen researchers have been working at the company’s laboratories in Leverkusen, Dormagen and Krefeld-Uerdingen on ideas for lightweight construction and energy efficiency. Material solutions are, for example, part of the plane’s pilot cabin, the wings and the motor gondolas.

High-tech on the soccer pitch

in heavy rain, its weight increases by no more than 0.1%, which means that the players are able to control it better.

The ball’s name and design are every bit as traditional as its insides are modern.

The Tango debuted at the 1978 World Championship in Argentina, and its successors provided for plenty of goals at subsequent championships in the 1980s.

The new ball sports the classic black and white design updated with colourful accents. The host nations’ national colours – red and white for Poland, yellow and blue

for Ukraine – have been immortalized in the triangles. Another unique feature is that unlike its predecessors, it does not have a glossy surface – matte balls are currently in vogue.

Bayer MaterialScience’s involvement in sports goes beyond soccer. Safer, more stable, faster – sports equipment such as skis, snowboards and inline skates also benefit from high-tech plastics. This also applies to other sporting goods. Raw materials from Bayer MaterialScience can be found in goggles, helmets and shoes.

High performance materials for fast, robust & precise soccer ball THE games at the European Soccer Championship will be played to the rhythm of the ‘Tango 12’, a cutting-edge synthetic ball that is fast, robust and precise. The adidas ball sports a new design and is based on proven materials from Bayer MaterialScience.

The surface texture of the official European Championship ball feels like denim, allowing for better ball control.

The shell is made up of five layers with a total thickness of 1.1 mm. These layers make the European Championship ball robust and accurate. The middle layer – an Impranil® foam containing millions of gas-filled microcells – is responsible for the optimal contact of the ‘Tango 12’ to the foot. The upper layers protect the foam from external influences and help keep the ball looking new longer.

Another specialty material from Bayer MaterialScience is used for a patented thermal adhesive layer that makes the ball virtually impermeable to water. Even 112

AUGUST / SEPTEMBER 2012

Five layers of the high-performance material Impranil from Bayer MaterialScience make the “Tango 12” accurate and robust

www.materialscience.bayer.com

â&#x20AC;&#x153;more than just a chemical supplierâ&#x20AC;?