PLASTIC MAKES ITS MOVE... Highly reinforced Durethan速 and Pocan速 high-modulus materials offer many different options for replacing diecast materials, such as aluminum or zinc.
AN OVERVIEW OF THE KEY ADVANTAGES: _high stiffness _high mechanical strength _potential for wall thickness reduction _good processability _better thermal conductivity, permitting earlier demolding _less warpage _reduced thermal expansion _lower tendency to creep _good surface finish despite high filling levels _good chemical resistance _substitution of considerably more expensive plastics _suitable for replacing metals in structural components
Thanks to ultramodern and efficient material formulations, these materials with their high reinforcement levels of 50 % to 60 % can generally be processed just as easily as a general-purpose grade with 30 % reinforcement.
For more info call 0800 006772 or visit www.plastichem.co.za Durethan速 and Pocan速 are registered trademarks of LANXESS AG
BY THE WAY ...
The Big Clean-up! 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 (bronwen.clarke@gmail.com) 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
THE 27th International Coastal Clean Up took place around South Africa on 15 September. Although heavy showers slightly damped the enthusiasm in KZN, Capetonians were blessed with a warm and sunny Spring Day as thousands of volunteers flocked to the beaches to help pick up and remove litter. A complete report from the audited results of this year’s coastal clean-up will be released at the end of October. The report will look at the makeup of the plastic litter recovered and analyze it. Now the industry’s coastal clean-up gurus, Douw Steyn and John Kieser of Plastics│SA, are taking the process even further and will host the African Marine Debris Summit from 1-3 November, at which they hope to get delegates from around the continent.
Divers dredged the Kalk Bay and on Simon’s Town harbours in the Cape day the occasion of Coastal Clean-up the in September and, well, enjoyed process
www.saplastics.co.za
Bigger not always better 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
Plastics Institute of Southern Africa
Association of Rotational Moulders of South Africa
Plastics Converters Association
PET Plastic Recycling
Plastics Federation
South Africa
of SA
Institute of Materials
ALTHOUGH most of us in the industry Kieser and Steyn take a very close by now have very realistic views about , interest in keeping our coasts clean what works and what doesn’t, you are they Now . enge chall big a which is Debris have to ask yourself why so few South coordinating the African Marine Summit in November African companies become globally involved. There certainly are good examples of international success in certain spheres (an example being the manufacture of pool cleaning equipment, where SA reigned for an extended period), but we mostly seem to be competing with Chinese, Taiwanese, Thai or other manufacturers who can produce products we know well with apparent ease and at better prices. It’s possible that these ‘new’ manufacturers had previously been subjected to similar foreign competition.
New BOPP manufacturer? WE HEAR a new manufacturer of BOPP films is to start up at Cato Ridge in KZN. The investment is apparently by a group of businessmen from India. Rumours about a rival BOPP manufacturer have swirled around for years, even decades. This is an issue which all manufacturers in any market have to deal with, but rumour and reality are very distant cousins. Let’s face it, it’s comforting for any customer to have more than one supplier, but putting up a large investment such as for an 8.7m wide Brueckner oriented film line, besides the major other infrastructure and related services required, is a big ask.
Haircut at 10pm! ON a recent visit to Turkey it was possible to have a haircut at 10pm! Now you will ask: who wants to have his hair cut at 10pm? I noticed that most of the other shops were open too. The way of doing business in Turkey is, not surprisingly, hugely different from that in South Africa: the strategy for keeping their shops open appears to be based on the thinking that any income is better than no income. Virtually every citizen in Turkey is involved in business activities, whether it’s growing a few tomatoes or herding a few goats … they’re all working. That culture is now also translating to bigger commercial enterprises, and investors in businesses there can virtually count on the METHING HAVE SO commitment of workers. … IF YOU TO SAY de: if you e bright si Look at th isdom to w of m e ge at have som rite to us w se ea impart, pl iafrica.com s@ tic as sapl
Volume 10 No 5
OCTOBER – NOVEMBER 2012
Contents Find out more at www.saplastics.co.za
INDUSTRY NEWS SAPRO Best Recycled Product of the Year ColorMatrix in Africa
12 14
58
SAPPMA: Pipe 2012 conference
24
ARMSA: Rotation 2012 conference
32
PETCO: Manufacturers & retailers realise
38
they are still learning
60
Temperature control units for oil up to 150°C
42
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TRAINING
UĂŠĂŠ i>ĂŒÂˆÂ˜}ĂŠV>ÂŤ>VÂˆĂŒĂžĂŠ
86
58
pressing local problems
FEATURE
98
90
s 3OLID STATE RELAY 332 INSTEAD OF heating contactor
103
SPORTS High-tech bikes
s 3IMULTANEOUS READOUT OF TEMPERATURE set-point and actual value s #LEAR ARRANGEMENT OF OPERATING AND indicating elements
DIARY Events coming up in 2012
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92
WORLD SORTEX powers ‘green bottle’ drive in UK
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Type 150 Smart
good employees
PERSPEX SA & XPS: Two companies, one vision
Temperature control units for water up to 90°C
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FEATURE
Materials research aims to solve
‌ for large injection moulds, extruders, rollers, autoclaves and other processing equipment
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ASSOCIATION NEWS
The challenge of ďŹ nding and keeping
High-performance temperature control units
Type 90 Smart
6
POLYCO rises to the challenge
REGLOPLAS
108
101
s !LL COMPONENTS EXPOSED TO WATER ARE made of non-rusting materials, hence long service-life s !CHIEVES ESTIMATED REDUCTION IN REJECTS AND INCREASE IN PRODUCTIVITY
ON THE COVER IN THE DYNAMIC world of Perspex South Africa, change is the only constant. Following on from the launch of Xtruded Polymer Solutions (XPS), the Port Elizabeth-based rigid plastic sheet extrusion facility, in October 2010, the group has been hard at work reviewing its overall business model and value offering to the marketplace. See page 92 for more information
JENOWILL SERVICES #ONTACT n 7ILLY 4SCHOPP 4EL &AX # ,ILLY 0ARK 2AILWAY 2D -ONTAGUE 'ARDENS #APE 4OWN JENOWILL IAFRICA COM WWW REGLOPLAS COM
THIS ISSUE The SAPRO Recycled Product of the Year competition has provided impetus for the development of new products
SAPRO design competition
Martin Wells
, Publisher
heralds new substitution trend ITH the process of material substitution having mainly run its course for the industry over the past four to five decades, the frequency of new product applications has slowed. Surprising, however, is the emergence lately of a trend for products made from recycled plastic to substitute rival materials in a wide range of applications as well as their use in new applications. COMMENT
W
Our main story in this issue is about the ‘Recycled Product of the Year’ competition coordinated by SAPRO (Southern Africa Plastic Recyclers Organisation), see pages 6-10. The programme was enthusiastically driven by Annabé Pretorius who deserves congratulations. Entrants in the competition achieved a high standard and deciding on the winners was a tough challenge for the judges. Farewell to a man who made things happen “THIS is no longer a ‘piet snot’ operation!” the little man was shouting. The sheer decibel level, notable for such a short, rotund man, was quite overwhelming. His office in Epping was very well appointed, with studded leather chairs, paintings by well-known, even famous artists, and the finest china on an antique side table. But in spite of the verbal assault, I noticed the gentleman before me had a mischievous sparkle in his eye. It was my first real encounter with Doug de Jager, erstwhile founder and CEO of Lenco group, which was then – in the mid-1990s – becoming one of South Africa’s top packaging groups. De Jager – who I instantly came to regard as the self-appointed ‘Napoleon’ of the local plastic packaging industry (in the Cape that is) –
4 OCTOBER / NOVEMBER 2012
had got to the top by force of character, determination and strategic skill. He was a man who achieved a lot from very little, as you will be able to read in his obituary in this issue. The story (page 53) compiled by former Lenco financial director Stan Stubbs is worth reading. De Jager was just 61 at the time of his recent passing and may have achieved even more had he remained involved in the industry in South Africa. Overall, though, Products made we salute his legacy. All from recycled industries require people material open who make things happen new opportunities (nothing happens otherwise) and in that respect Doug set a fantastic example. Show ‘season’ THIS issue we also look at the ARMSA and SAPPMA conferences. The roto moulders’ event was held as a ‘bosberaad’ over two-and-a-half days in the Waterberg and many of you will agree, I think, that the bush experience is one of the best things about life in Africa, and is frequently what visitors to the country seek most. The SAPPMA conference was a one-day event in Midrand which has been come very popular, notably with engineers and town planners (the people who specify what pipe, or other materials, are to be used). The SAPPMA team have done well to create interest in the user market and the fact that close to 200 people attended the event is very impressive. Well done to the ARMSA and SAPPMA teams.
where quality is action
A-PET
INDUSTRY NEWS
Best Recycled Product of the Year showcases innovation & diversity
WINNERS ALL THE WAY! THE South African Plastics Recyclers Organisation (SAPRO), with the support of Plastics|SA and the Packaging Council of South Africa (PACSA), announced the winners of the annual “Best Recycled Product of the Year Competition” at a gala awards dinner held at Gallagher Estate in Midrand in September.
The competition was one of the highlights of the local plastic industry’s Clean Up South Africa Week (10-16 September), and encouraged brand owners and industrial designers to consider recycled plastics as a material of choice. Brand owners from around the country, retailers and association leaders attended the ‘Oscar awards of the plastics industry’ which celebrated innovation, sustainability and technical developments in the recycling industry. “We were thrilled with both the quality and quantity of the entries we received this year, proving that the plastics recycling industry is growing in size, sophistication and value,” said Douglas Greig, Chairman of SAPRO.
Adding a touch of style to the awards – Monique Holtzhausen-Hinds (PR for PlasticsSA and Sapro), Yanna Erasmus (Editor: ReSource magazine), Adri Spangenberg (Polystyrene Packaging Council), Douglas Greig (Tuffy and Chairman of Sapro), Annabe Pretorius (Sapro), Riaan Garforth-Venter, Michelle Garforth-Venter (MC), Anton Hanekom (Plastics|SA), and Monya Vermaak (Plastics|SA).
GOLD D AWAR
OVERALL WINNER FOR 2012
Michelle Garforth-Venter (MC for the awards evening) shares a laugh with Craig Hall of Lasher Tools
Lasher Ecobarrow
Also winner in category for products containing a certain % post-consumer recycled content The evening clearly belonged to the Lasher Ecobarrow, manufactured and distributed by Lasher Tools and the recipients of the PACSA Trophy for Best Recycled Products. Lasher Tools were also finalists in the category for products containing a certain percentage postconsumer recycled content with their poly hoe and poly pick handles. Lasher is the largest manufacturer of these products in the Southern Hemisphere with a range in excess of 1200 different stock items. Their products go into the DIY, construction, mining, agriculture and industrial markets. Due to increasing steel prices and market demand for better quality tools, Lasher started to explore the possibilities of making better quality
entered their EcobarOverall winner – Lasher Tools, who plastic materials led recyc the of liers row, with the supp arrow: Front from left, used in the manufacture of the Ecob ye (recycled material Hansie Terblanche from Sindawon amid (recycled matePlast from man Gold les Char supplier), amid (recycled maPlast from ck Kello lyn rial supplier), Caro Richard Spence and al Kend terial supplier), Crail Hall, Ian ch from Transpaco from Lasher Tools, Jaco Breytenba O Chairman Recycling and Douglas Greig, SAPR
traditional products using different materials. With the world focusing on environmental issues, Lasher embarked on a mission to use recycled plastic as one of its main components in manufacturing. Consumers are bombarded with a wide range of tools and utensils in the DIY, gardening, construction and agricultural market with the bulk of the products being imported to South Africa from the Far East. Lasher’s Proudly South African Ecobarrow, however, sports a design that was clearly and properly thought-through. The end result was an attractive, ergonomically pleasing product that will outlive most of its users whilst maintaining the strong brand identity. Lasher obtained the moulding technology to manufacture the complete product in-house with state of the art equipment. With the world’s focus on environ-
6 OCTOBER / NOVEMBER 2012
mental issues, recycled materials came as a natural choice. Only the rim and axle are made from virgin materials. “This year’s awards have once again proven that South Africa is amongst the world’s leaders in mechanical recycling of its plastics products. Each of the entries we received was a winner in its own right. The quality of the products are improving each year as brand owners become ever mindful of consumer acceptance and the aesthetic appeal of their products. “At the end, the entries that showed longterm environmental commitment without superfluous green washing and proved that recycled plastic can be both beautiful as it is strong, durable and environmentally responsible as it ensures that the material and the energy is not lost,” said Greig.
MERIT D AWAR
CATEGORY WINNERS
JUDGES SPECIAL MENTION
“We were thrilled with both the quality and quantity of the entries we received this year, proving that the plastics recycling industry is growing in size, sophistication and value.”
Bottleworx Building System The Bottleworx Building System particularly impressed the judges with its unique building system based on re-using specially designed PET bottles of 500 ml, 1 litre and 2 litre volumes to fill and insulate walls. Using an interlocking cubic design, Bottleworx transforms ordinary packaging into a multi-functional material that permanently removes plastic and other waste from the environment. Empty containers are up-cycled to be used as building blocks for almost anything and can be used to build houses, schools, clinics as well as bed bases, couches and even educational toys.
OVERALL WINNER
Ecobarrow from Lasher Tools JUDGES SPECIAL MENTION • Merit award: The Bottleworx Building System NOVEL AND ARTISTIC PRODUCTS
NOVEL AND ARTISTIC PRODUCTS Articles made from used and discarded plastics products
GOLD D AWAR
• Silver award: The Tabitha Star light from Libere Foundation
Eco Smart Group for their Geyser Blanket
MIXED RECYCLED MATERIALS
This entry impressed the judges with its relevance in saving energy as well as using waste materials. The fact that it sells for less than the official geyser blankets in the market is excellent despite the labour intensive nature of the manufacturing process. “The product has enormous potential to create awareness”, Greig explained.
SILVERD AWAR
• Gold award: Cyclo roof tiles from Cyclocor KZN • Silver award: Tree Hugger bench from NewLife Plastics PRODUCTS CONTAINING A CERTAIN % POST-CONSUMER RECYCLED CONTENT
Tabitha Star Light entered by the Libere Foundation
• Gold award: Ecobarrow from Lasher Tools
This stunning light is made from PET beverage bottles and was designed by 16 year old Tabitha van der Merwe from George. It is a real novelty item with good aesthetic appeal and will draw attention to the re-use of waste packaging.
• Silver award: Unilever sunlight dishwashing liquid bottle from Unilever • Silver award: Lavaplastic range of products from Southgate Recycling
A panel of plastics experts was asked to judge products based on various criteria • Life expectancy of product • Sustainability and longterm demand and market acceptance for product (i.e. will it still sell in 5 years' time?) • Tonnage (potential tonnages) diverted from landfills and
• Gold award: Geyser blanket from The Eco Smart Group
converted into a product • Replacement of alternative materials • Technical achievements in manufacturing excellence to overcome recycled material challenges
• Measures taken to ensure product consistency and customer satisfaction despite recycled material content • Potential to create consumer awareness of plastics recycling, etc.
OCTOBER / NOVEMBER 2012 7
PRODUCT MADE FROM 100% RECYCLATE • Gold award: rPET Lomold pallet from Lomold • Silver award: Tuffy refuse bag from Tuffy • Silver award: Chicken nests from M & S Plastics
INDUSTRY NEWS
MIXED RECYCLED MATERIALS “In this category, the judges particularly looked at the originality of the design and if the product was well put together”, Greig said. In most instances, the polyolefins are blended together, such as low density polyethylene, high density polyethylene and polypropylene. Other, non-plastic materials such as sand, wood dust, saw dust, and cellulose or wheat chaff can also be mixed with the plastics. These bulky durable products are normally huge and heavy and consume high tonnages of materials but only a few of each design is typically made by a manufacturer.
GOLD D AWAR
Cyclo Roof Tiles entered by Cyclocor KZN
This company only started in May 2012 manufacturing roof tiles, but already boast a couple of designs in various colours. They managed to secure off-take agreements for 100% of their current production capacity of 100 000 tiles per month. The waste plastics are sourced from community based waste management companies and collectors. The tiles will reduce the building cost of houses as the reduced weight necessitates fewer trusses and roof support beams. Cyclocor will expand their manufacturing facilities in the next year with a new factory in Gauteng as well as in the Western Cape.
New Life Plastics for their Tree Hugger Bench
SILVERD AWAR
The raw material (planks) were sourced from Extruwood and designed and manufactured by New Life Products in Cape Town. The strong, simple design results in a product that will fit just about anywhere. It will look equally good in a public park or garden as it will in a suburban private garden. The assembled tree hugger bench was exceptionally steady, which impressed the judges.
PRODUCTS CONTAINING A CERTAIN % POST-CONSUMER RECYCLED CONTENT The brand owners are under constant pressure from the environmentally conscious consumer to become more ‘green’. Consumers want to know that their packaging and plastics products are not damaging the environment and there is a major tendency for consumers to want to ‘feel good’ and to be ‘doing the right thing’ when they are buying a product. The average consumer is not prepared to sacrifice his popular brand or to make any sacrifices himself, but he is looking towards the brand owner to assist him in his environmentally conscious decisions. “In this category, it was therefore important to the judges that the products did not lose their perfect and aesthetically pleasing appearance and to be completely functional. At the end of its useful life, the product should be allowed to enter the recycling stream and be fully recyclable,” explained Greig.
SILVERD AWAR
Unilever Sunlight dishwashing liquid bottle
“Recycled PET (RPET) only recently became available in South Africa and the demand exceeds the supply. At current production levels, 300 tons of PET is kept away from landfill. Standing on just about every kitchen zinc in the country today is a bottle of Sunlight Dishwashing Liquid that contains 25 % of recycled PET”, said Greig. Unilever is aiming to produce the bottle from 100% RPET as soon as they can get enough of it. “It is crucial that leading brands such as this, should lead the way in educating consumers as to the merits of recycling and the positive impact that this move has and will have on the environment. SAPRO would like to see the bottle introduced to the market proudly carrying its recycled content and proclaiming its environmental accountability”, he added.
8 OCTOBER / NOVEMBER 2012
SILVERD AWAR
Southgate Recycling for their Lavaplastic range of products This woven lattice was originally developed for fencing in coastal dune rehabilitation. The demand for lavaplastic has subsequently developed for the domestic DIY market for garden screening, edging, outdoor furniture and decoration. This PVC product is maintenance free and has an estimated life span of more than 30 years. The recyclable materials for the lattices are obtained from industrial- as well as post-consumer PVC waste.
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INDUSTRY NEWS
PRODUCT MADE FROM 100% RECYCLATE SAPRO received 11 entries in the 100% recycled material category. Recycled material from industrial and post-consumer sources qualified. The judges evaluated the products for their fit-for- purpose and consumer acceptance. Due to the inconsistency of raw material of this nature, attention was also given to the technical achievements of the manufacturer to ensure process stability and product consistency. This is also the category that used the highest tonnage of post-consumer waste.
rPET Lomold pallet by Lomold
GOLD D AWAR
The biggest challenge with plastic pallets today is the ability to match wood pallets both in cost and load carrying capacity. In order to match the desired cost profile, the weight of the LOMOLD Pallet needed to be approximately half that of equivalent plastic pallets, while still delivering high performance.
Tuffy refuse bag
SILVERD AWAR
“Tuffy runs 6 000 tons of material through its plant every year, equating to 240 million refuse bags. The company manufactures all its black refuse bags from 100% recycled material, the majority of which is post-consumer. Tuffy has become the first organisation in South Africa to receive SGS accreditation for having fully recycled content in their refuse bags,” commented Rory Murray of Tuffy.
SILVERD AWAR
M & S Plastics for their chicken nests
“The nest is blow-moulded from mixed colour recycled high density polyethylene and used by breeding farmers and egg laying farms especially for free range eggs. M & S Plastics modified an existing mould with an insert to be able to prevent recapitalising. The nest is well designed, with a pronounced “lip” in the front which prevents wood shavings, a major expense to chicken farmers, from being kicked out of the nest. The judges applauded the way that a solution was developed to save the customer considerable costs without incurring large cost themselves”.
“The judges applauded the way that a solution was developed to save the customer considerable costs without incurring large cost themselves”. 10 OCTOBER / NOVEMBER 2012
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M A S T E R B AT C H
P I G M E N T S
L I Q U I D S
A D D I T I V E S
JUST BRIEFLY Gazelle exonerated by Competition Commission GAZELLE Plastics was recently found ‘not guilty’ by the Competition Commission Tribunal, exonerating the company from its purported involvement in the ‘plastic pipe cartel’ of 2007-2009. The Commission had alleged that Gazelle Plastics and Gazelle Engineering of Krugersdorp, now part of the First Tech Group, had been involved in meetings with other pipe manufacturers in which they fixed prices‚ rigged tenders and divided markets by allocating contracts and customers. Gazelle contested these allegations and, years after the Competition Tribunal hearings took place in 2009 and 2010, the Commission recently dismissed the case against the businesses. Pieter de Frey, who was appointed CEO of Gazelle when the company became part of the First Tech Group, said “It was a tough road for us emotionally and we invested significant time and resources in the process. We together with the previous Gazelle owners believed in the innocence of Gazelle and this was ratified by the tribunal.”
Renolit films to be imported from now RENOLIT group, an international manufacturer of technical plastic films, has ceased production in South Africa. The production unit at Sasolburg has shut. The group’s range of films will from now be imported and be available from the Renolit depot in Kempton Park. Renolit’s thermoplastic films are used in a wide range of applications, including the automotive, furniture, building components and consumer electronics sectors (with decorative surface finishes) as well as for sealing roofs, underground structures and lining swimming pools. Recyclable composite panels incorporating natural fibres for the building sector and automotive industry are also supplied. The group operates about 30 production and sales units around the world. www.renolit.com
Restructuring at BASF plant in PE BASF South Africa will be downsizing its operations at its Mobile Emissions Catalysts site in Port Elizabeth. An extended reduction in the expected medium-term demand for products manufactured at this facility saw the site undertake an organizational restructuring exercise resulting in 53 current positions becoming redundant. The site currently employs 308 staff. www.catalysts.basf.com 12 OCTOBER / NOVEMBER 2012
PolyOne Corporation to expand via
ColorMatrix in Africa Committed to a global ‘invest to grow’ strategy Middle East and African operations. “Opening this facility in Cape Town will provide us with a strong customer-focused presence in this important region.” “When PolyOne acquired ColorMatrix last year, we committed to a global ‘invest to grow’ strategy that would add value to our The new facility, in the Montague customers and our shareholders. Our new Gardens industrial precinct in Cape Town, facility in South Africa illustrates our commitwill support customers throughout Africa. ment to this strategy,” Services will include said Robert Patterson, sales, technical supThe immediate focus of the chief operating officer port and an on-site operation will be to deepen of PolyOne. colour laboratory for support for customers who “While these operarapid colour developmanufacture products such tions will initially focus ment. The immediate as PET containers for the on ColorMatrix prodfocus of the operation beverage and personal ucts and services, this will be to deepen supcare markets affords us an excellent port for customers who foothold to leverage manufacture products other PolyOne businesses and services such as PET containers for the beverage throughout the region in the future.” and personal care markets. “ColorMatrix is dedicated to helping our Product distribution customers grow and win by advancing the Dennis Williams, general manager of performance and value of polymer-based ColorMatrix South Africa, said the focus goods globally,” said William Ravenna, was to deliver quick and efficient product ColorMatrix managing director for Europe,
COLORMATRIX, a subsidiary of PolyOne Corporation, a leading innovator of liquid colour and additives for plastics, opened a new facility in Africa in August.
A toast to success – Raising their glasses to wish ColorMatrix a successful future in SA are Dennis Williams (general manager of ColorMatrix South Africa), William Ravenna (ColorMatrix managing director for Europe, Middle East and African operations) and Alan Winde, Provincial Minister of Finance, Economic Development and Tourism
By using a hand-held spectrophotometer, the user is able to perform an instant colour match from a suitable sample. DosiXpress™ then calculates a matching colour formulation based on very speciďŹ c quantities from a range of base colours
he explained. The new facility has capacity to store products in bulk, according to market requirements, from ColorMatrix’s entire portfolio of liquid colorants, additives and dosing equipment. Initially there will be ďŹ ve employees on site. The 1800m² facility comprises ofďŹ ce space, a colour laboratory and warehouse space. A locally based technical service engineer (TSE) will deliver technical support
to customers in South Africa. ColorMatrix TSEs work on-site to support customer trials, production start-ups and provide ongoing customer production support. One of the most interesting aspects of the new ColorMatrix facility is its DosiXpress™ ‘Colour Matching Cell’, a rapid colour match formulation system that accelerates the colour development process. www.polyone.com
DosiXpress™ Color Matching Cell The DosiXpress™ Color Matching Cell allows ColorMatrix to deliver a rapid colour development service for its customers, streamlining the process, reducing waste and inventory and allowing them to increase speed to market for their products. By using a hand-held spectrophotometer, the user is able to perform an instant colour match from a suitable sample. DosiXpress™ then calculates a matching colour formulation based on very speciďŹ c quantities from a range of base colours. The formulation can then be used to produce a small sample for trials or a small production run and this entire process can be completed in a matter of minutes, signiďŹ cantly minimising the time and resource traditionally associated with the colour matching process.
OCTOBER / NOVEMBER 2012 13
ABOUT POLYONE PolyOne Corporation, with 2011 revenues of $2.9 billion, is a premier provider of specialized polymer materials, services and solutions. The company is dedicated to serving customers in diverse industries around the globe, by creating value through collaboration, innovation and an unwavering commitment to excellence. Guided by its Core Values, Sustainability Promise and No Surprises PledgeSM, PolyOne is committed to its customers, employees, communities and shareholders through ethical, sustainable and ďŹ scally responsible principles.
ColorMatrix’s new 1800m² facility has capacity to store products in bulk, according to market requirements, from ColorMatrix’s entire portfolio of liquid colorants, additives and dosing equipment
open ColorMatrix, a leading innovator of liquid color and additives for plastics and a subsidiary of PolyOne Corporation, is now open in South Africa
Unit 3, Northern Precinct East Building, Montague Business Park Topaz Drive - Milnerton, Cape Town
INDUSTRY NEWS
distribution and colour development as well as improved customer support and technical back-up. “There is no manufacturing taking place on site and all primary products will be brought in from our UK (Knowsley) and Netherlands (Eindhoven) manufacturing sites. Our technologies and services are designed to add value to customers operating in the PET packaging, PVC extrusion and injection moulding markets,�
One of the most interesting aspects of the new ColorMatrix facility is its DosiXpress™ ‘Colour Matching Cell’, a rapid colour match formulation system that accelerates the colour development process
Working to ensure no supply disadvantage occurs across all parties
INDUSTRY NEWS
The Polyolefin Plastic Recycling Company, POLYCO, in existence for just over a year, has seen a reasonable share of success and also faced some interesting challenges. POLYCO hopes to realise improvements for the industry in terms of facilitating the recycling of more post-consumer polyolefins, improving the industry’s environmental image, training opportunities and strengthening the relationship with government – in short, everything that a robust industry requires. Led by the major plastic packaging converters in South Africa, POLYCO was established in August 2011 specifically to promote and grow the collection and recycling of post-consumer PP, HDPE, LDPE and LLDPE packaging materials as required of this industry sector in terms of its obligations to Government under Extended Producer Responsibility (EPR) as covered in the Industry Waste Management Plan for Packaging and Paper. POLYCO derives its income from a R100/ton voluntary recycling levy on all polyolefins resin purchased by the industry, and used for packaging. POLYCO will use these funds to support polyolefin recyclers, collectors, reclaimers and those businesses involved in end-use product development. Successes to date Achievements to date include setting up the Company, constituting the Board and complying with corporate governance. Obtaining the buy-in
and support of the major polyolefin converters who pay the levy on polyolefin packaging resin is a major ongoing challenge. Thus far the large polyolefin converters have all signed up but many other converters are playing the waiting game. Says Jeremy Macintosh, Chairman of POLYCO: “It is useful to remind ourselves of why an organisation such as POLYCO is needed. Firstly it is the right thing to do for polyolefin growth; litter is bad for the business. Polyolefins are the ‘pack of choice’ for the consumer and none of us want growth held back through a negative environmental perception. “Secondly, the alternative will be government intervention, which we want to avoid at all costs, ensuring that the polyolefin industry is not subjected to legislation over which it has little or no control. We only have to think of what happened with the plastic bag levy to realise that the polyolefin industry must manage its own destiny. PETCO is a good example of what can be achieved. “I urge all those converters who are still considering whether to, to join POLYCO and the rest of the polyolefin industry, in its efforts to create a growing and sustainable polyolefin recycling initiative and be part of the future.” POLYCO has developed excellent relationships with both Sasol and Safripol, the two material suppliers with whom the organisation works very closely, and one of which, Safripol, represents both polymer suppliers on the POLYCO Board. The material suppliers are critical to the success of POLYCO since they collect the levy on behalf of POLYCO. Macintosh says all parties are keen to
Industry embarks on ground-breaking research project THE Manufacturing, Engineering and Related Services Education and Training Authority (merSETA), in association with Plastics|SA, has launched an innovative pilot study with the aim of developing a better understanding of the shape and size of the plastics industry in South Africa. According to Danny Sour, chairman of the merSETA Plastics Chamber, there are various factors impacting on the industry’s future. “We are hoping to identify the key drivers for change, with particular reference to skills priorities and possible growth scenarios with this industry-wide research project,” said Sour. As the umbrella body representing the local plastics industry, Plastics|SA has been tasked with the responsibility of managing the communication to industry partners and for collecting information and feedback from its members. “The growth we have experienced in the plastics manufacturing, recycling and
14 OCTOBER / NOVEMBER 2012
related industries during the past five years has left us with a knowledge gap regarding the exact shape and size of our industry,” said Anton Hanekom, executive director of Plastics|SA. “We are hoping to gather up to date and vitally important information about our industry with this research project,” he added. Although the number of people employed in the industry is estimated to be between 45 000 and 63 000 people, exact figures are currently unavailable. Similarly, information about industry demographics such as race, age, gender and disability, or about the skills profile and needs of employees is either non-existent or outdated. Specifically, it is hoped that the gathered information will help to achieve the following objectives: Mapping out and describing several jobs in the industry to avoid any misunderstanding and confusion about job descriptions, remuneration
Independent researchers Fiona Farquharson and Christoph Vorwerk and have been appointed to conduct empirical research
and skills levels; Introducing an effective forecasting dimension for the industry, such as future anticipated growth and challenge areas and how the local plastics industry will position itself in terms of Chinese imports, global downsizing, the green economy, waste, entrepreneurship and innovation in the local market.
Jeremy Macintosh, Chairman of POLYCO: “I urge all those converters who are still considering whether to, to join POLYCO and the rest of the polyoleďŹ n industry, in its efforts to create a growing and sustainable polyoleďŹ n recycling initiative and be part of the future.â€?
promote the improvement of waste management and recycling of post-consumer polyoleďŹ n products and have entered into agreements with POLYCO that they will collect the levy on the organisations’ behalf Challenges POLYCO recently advertised a Call for Proposals that will increase post-consumer polyoleďŹ n recycling. The organisation is looking for partners that will enable POLYCO to meet the targeted tonnage of post-consumer polyoleďŹ n recycled, develop new end-use markets, assist with the establishment of collection and drop off centres and progressively build recycling awareness through compelling and focused messaging. The ultimate fate of recycled polyoleďŹ ns will depend on the development of more economical recycling technologies, more effective collection and sorting, a better understanding of the behaviour of contaminants in recycled materials and the evolving regulatory climate for recycling. “We understand that plastic recycling issues are complex. Important aspects include the environmental impact of growing natural resource consumption, the need to revise collection and reprocessing infrastructures, the relatively new ‘eco-design’ approach to products, and life cycle analysis of ‘cradle-to-cradle’ use. We hope to ďŹ nd partners that can assist us to begin to resolve these challengesâ€?, said Macintosh.
Sheryl Ozinsky, CEO of POLYCO: “POLYCO will be urging importers to assist in collecting levies on the same basis as SASOL and SAFRIPOL do. They beneďŹ t from the growth in our industry, almost more than the local guys as any shortfall in supply is picked up by them, the importers.â€?
who are leading POLYCO, are requesting their suppliers to add the levy onto their raw material invoices, then the local importers should oblige and contract with POLYCO accordingly,� Ozinsky added. Other material importers are those that do not take title of the imported material as intermediaries. In this instance, with levy title passing from an overseas-based supplier directly onto the local buying converter, levy collection on material invoice is even more of a challenge to try and implement. “Either way all material imports of those converters who have signed up to POLYCO are covered by the POLYCO import declaration system, the same POLYCO agreement that gives consent for collection of the levy via SASOL and SAFRIPOL. Under this system all the contracted converters declare to POLYCO those tons that they have imported each month for POLYCO’s direct invoicing and collection of those levies concerned,� Ozinsky explained. “Ultimately POLYCO is working to ensure no supply disadvantage, real or perceived, occurs across all those parties concerned. It’s a win-win solution for the industry, an advocate for achieving world-class standards on recycling. To achieve this everyone involved from the raw material producers, through to manufacturers, retailers, consumers and recyclers need to play their part in the solution,� she added. OCTOBER / NOVEMBER 2012 15
Material importers Another challenge revolves around getting the suppliers of imported polyoleďŹ ns to support POLYCO. These importers supply a large percentage of total polyoleďŹ n consumption in SA. At least one importer moves about 5 000 tons a month, and there are about 10 material importers active in the local market, most of them supplying less than that. These importers tend to supply even more when the local manufacturers are unable to supply, for example, speciďŹ c grades or because of technical problems at plants, a reality for polymer material manufacturers around the world. SA Plastics Magazine has learned that at least two of these importers feel that the market is very tight for most converters at present and they do not want additional costs - even if the POLYCO levy is the right thing for them to do. Says Sheryl Ozinsky, CEO of POLYCO: “POLYCO will be urging importers to assist in collecting levies on the same basis as SASOL and SAFRIPOL do. They beneďŹ t from the growth in our industry, almost more than the local guys as any shortfall in supply is picked up by them, the importers.â€? If a converter imports polyoleďŹ ns directly, they would need to declare the tons imported and pay the levy directly to POLYCO. Ozinsky says POLYCO would like to see material importers also include the POLYCO recycling levy on their invoices, in much in the same way as they charge their customers for local VAT. “Import declarations are the responsibility of the converter and POLYCO would like to see full disclosure in this regard. Ultimately, if their customers (South African polyoleďŹ n converters),
For the collection and recycling of post-consumer & '
Request for Proposals Opportunity to partner with POLYCO in the recycling of plastic packaging. POLYCO, led by the major plastics packaging converters of South Africa, has been established to promote and grow the collection and recycling of post-consumer PP, HDPE, LDPE and LLDPE packaging materials as is required in terms of its obligations to the South African government under extended producer responsibility. A mechanism has been created by POLYCO to provide
This is a call for proposals under three distinct categories: Category “A� Projects: Substantially increase the collection These are large-scale projects that currently have each of the following within their value-chains: ! " Category “B� Projects: Contribute to the visible promotion of plastics collection and recycling. They do not necessarily have to involve " Category “C� Projects: # such as virgin displacement for a manufactured item. #
Deadline for proposals is Monday 05 November by 5pm. No late submissions will be accepted. $
% Ms Bronwyn Durham Tel: 078 095 5900 E-mail: accounts@polyco.co.za www.polyco.co.za
INDUSTRY NEWS The Al-Jubail Petrochemical Company (KEMYA) manufacturing joint venture where SABIC and affiliates of ExxonMobil will construct a world-scale specialty elastomers facility
Tot investmal of US $ ent 3 billion .4
SABIC, ExxonMobil proceed with specialty elastomers project in Al-Jubail SAUDI Basic Industries Corporation (SABIC) and affiliates of ExxonMobil will construct a world-scale specialty elastomers facility at the Al-Jubail Petrochemical Company (KEMYA) manufacturing joint venture. The facility will be integrated with the existing Al-Jubail complex and completion is anticipated in 2015. Both companies have approved the next stage of project development, the engineering, procurement and construction (EPC) phase. With a total investment of US $3.4 billion, which will be financed from shareholder and or third party debt, the facility will have the capacity to produce up to 400 000 tons per year of rubber, including halobutyl, styrene butadiene, polybutadiene, and ethylene propylene diene monomer (EPDM) rubbers, thermoplastic specialty polymers, and carbon black to serve local markets, the Middle East and Asia. KEMYA has awarded the engineering, procurement, and construction contracts for the elastomers facility to: Daelim Industries, Technip, and Tecnicas Reunidas. Al-Jubail Petrochemical Company (KEMYA) is a 50-50 joint venture between SABIC and Exxon Chemical Arabia Inc., an affiliate of ExxonMobil Chemical Company. The two companies have collaborated closely since the joint venture was established in 1980, producing polyethylene, ethylene and propylene. The new synthetic rubber project represents a significant broadening of KEMYA’s product portfolio. Associated with the new KEMYA 16 OCTOBER / NOVEMBER 2012
elastomers facility is the establishment of the High Institute for Elastomer Industries (HIEI), a vocational training centre in Yanbu, a Product Application Centre in Riyadh, and thermoplastic polyolefin (TPO) compounding and inventory management facilities in Al-Jubail. The HIEI will employ innovative polymer science education programmes developed at the University of Akron Research Foundation (UARF), in Ohio, USA to train Saudis for the Kingdom’s developing elastomers conversion industry. “The KEMYA elastomers facility demonstrates our commitment to build and champion a first-rate rubber industry in Saudi Arabia that supports job creation, develops downstream industries and helps diversify the national economy,” said Mohamed Al-Mady, SABIC Vice Chairman and CEO. An expanding transportation infrastructure in the Middle East and Asia-Pacific region has created strong demand for rubber products. The new world-scale KEMYA elastomers project will help meet this ever-growing demand. The facility will rely on commercially competitive, high-impact technologies, including proprietary ExxonMobil EPDM, thermoplastic elastomer (TPE) and halobutyl rubber technologies. www.sabic.com
New GM for SABIC in SA SABIC has appointed Dr Antonie Potgieter as their new General Manager in Southern Africa. SABIC is a leading global producer and marketer of polymer, chemical, specialty chemical, steel and fertilizer products through various channels. Dr Potgieter has a PhD in Polymer Science and an MBA (Finance) from the University of Stellenbosch. Prior to joining SABIC he spent six years in the defense industry with Somchem, 14 years in the petrochemical industry with Sasol as Principal Scientist, Process Engineer, Head of the Technical Department and Supply Chain Manager respectively. He joined SABIC in November 2006 as Project Director, based in Riyadh, Saudi Arabia. He led a multi-national project team of several hundred employees and consultants with an objective to transform SABIC’s global supply chain to a world class operation. Project EMDAD was a huge success and is contributing generously in improving operational efficiencies and customer service across the globe. His appointment as GM of SABIC Southern Africa became effective in January this year. One of the highlights of Dr Potgieter’s career so far includes the developing and patenting of a new copolymer that is being sold commercially today. Under his leadership, Project EMDAD led to the successful development and implementation of leading global supply chain capabilities at SABIC. More than 60 million tons of product move through SABIC’s supply chain annually. As General Manager he will be responsible for leading his team towards SABIC’s goals and aspirations. These include growing the market share into sub-equatorial Africa, social responsibility programmes, supporting industry initiatives, identifying potential investment opportunities, fostering good customer and service supplier relationships as well as ensuring good corporate governance. These are all initiatives high up on SABIC’s agenda. “South Africa and the region have great growth potential. I see a bright future for SABIC in Africa and more specifically, Southern Africa. I believe that South Africa can benchmark from Saudi Arabia how industry and government collaborate in managing their natural resource wealth, grow the economy, develop their people capital and create jobs,” says Dr Potgieter.
DESIGN + PERFORMANCE SABIC produces the raw materials used for a wide range of downstream products – from world class stadia to toys, furniture, pipes, automotive parts, and other durable high-performance products. SABIC’s products touch the lives of millions of people around the world. The company works closely with its customers to achieve their commercial ambitions and provides the right level of support to meet their manufacturing challenges. SABIC offers its customers a wide range of polymer products such as LLDPE, HDPE, Bimodal HDPE, PET and LDPE.
SABIC South Africa (Pty) Ltd 18th Floor, Metropolitan Centre, 7 Coen Steytler Ave, Cape Town, 8001 Tel: +27 21 409 6100 Fax: +27 21 409 6101
www.sabic.com
PHOTOS: KERRY WRIGHT (MILLERS LOCAL, PORT ELIZABETH)
The new fins are produced in an attractive shade of blue
Both the fins and plugs are injection moulded in rPET
Peter Barclay of Bottlemakers and Cliff Hamilton, surfer-engineer who came up with the idea, keep an eye out for a good wave
Surfboard fins in rPET Made in Port Elizabeth ‘Fins-In’ catch a good wave BOTTLEMAKERS of Port Elizabeth has been involved in the exciting development of a new surfboard fin produced in recycled PET (rPET). When Peter Barclay of Bottlemakers was visited at his production plant at Seaview near PE by local surfer and engineer Cliffy Hamilton, the last thing he had on his mind was a new injection moulding project. Up till that point Bottlemakers had been producing PET containers plus closures and handles for the larger containers. Hamilton asked Barclay if it was possible to produce fins in PET, and the answer was “Of course … we’ll try”. The decision to use rPET was a logical step, giving the new product a ‘greener’ footprint. A considerable amount of R+D has gone into the development of the ‘FinsIn’ product since, and it looks like the new design has been a big hit with local surfers. Fins used traditionally had the disadvantage that, in the event of impact, the plugs were often damaged as well,
18 OCTOBER / NOVEMBER 2012
which in turn also resulted in damage to the board – which is usually costly to repair. By comparison, the ‘Fins-In’ products tend to snap off above the plug, resulting in less or no damage to the plug and board. Giving impetus to the initiative was the fact that fins used to date were expensive, and the new variation comes in at an advantageous price – meaning that demand has been good. Although Bottlemakers is involved in ISBM manufacture of PET containers, the rPET used is not from its own production scrap: it is using the ‘Phoenix’ rPET from Extrupet of Johannesburg, and the results have been good. The fins are thin, and the result is that the mouldings achieve an attractive sheen merging from a resonant blue at the core to virtual transparency at the edges, which has proved attractive to surfers. The plugs are also produced in rPET. The new fins do presently have their
limitations, however, specifically in that they are suited to waves of a maximum of about 2m. This is in fact a common wave height along the southern Cape coast, and particularly in the PE/Jeffrey’s Bay area – coincidentally one of the most popular surfing areas in the world. Barclay and his team are looking into adding glass reinforcement to the material to produce stiffer fins for bigger waves, when it is necessary for the surfer to hold his or her line. • BOTTLEMAKERS: P. 041 364 2025; BOTTLEMAKERS@TELKOMSA.NET
www.millerslocal.co.za
INDUSTRY NEWS
Mould Base SA enters the market New company will supply mouldbases, mould components, ancillary equipment to Southern African market AFTER 26 years in manufacturing, Dave Moore has decided to close Contractools, the KZN family business that he has managed for the last 20 odd years. Labour pressures and small returns were the primary reason for the closure. He also wanted to try something different and challenging – and that aspiration has come true with his new venture, Mould Base SA, that is allied to the plastics conversion industry. Dave has secured an agency with LKM in China to supply their mouldbases and other mould components into the Southern African market. LKM is a big player in the mouldbase industry and supplies their products worldwide. “LKM’s quality is excellent and they are a very impressive company all round,” says Dave.
Along with standard and tailor made mouldbases, the company will be stocking a range of preground tool steel plates and other mould components, such as interlocks and pillars and bushes. Other equipment which will be carried includes specialised swivel lifting points which are perfectly suited to injection moulding and tool making. These are sourced from Yoke Industries in Taiwan. Photonic systems for mould protection from Suresee and a range of ancillary equipment for injection moulding will soon be announced. Dave says that the first container of mouldbases and components has arrived and already sales are good. “A shipment of lifting points arrived in the middle of September and a large packaging
Dave Moore of Mould Base SA unpacks his latest consignment from LKM in China. Mould Base SA will supply LKM’s mouldbases and other mould components into the Southern African market. LKM is a big player in the mouldbase industry and supplies their products worldwide
company has shown interest in a series of photonic systems as well,” he adds. Mould Base SA will be exhibiting at Afrimold from the 10-12 October and Dave invites all his friends and acquaintances to visit him at stand C21 and discuss their needs with him. All stock will be held in Pietermaritzburg and can be supplied countrywide. • DAVE CAN BE CONTACTED ON 083 675 8325 OR BY EMAIL AT MOULDBASESA@GMAIL.COM. OCTOBER / NOVEMBER 2012 19
AfriMold programme online now THE AfriMold conference, from 10-12 October at the Gallagher Convention Centre in Midrand, is being hosted by the Toolmaking Association of South Africa (TASA), aimed at providing support and assistance to the tooling industry from the ground up. The programme offers valuable information to assist industry to revitalize for sustainable growth and future development. Most importantly, it presents effective methods to improve production standards and international competitiveness. If you are involved in manufacturing, you need to attend. YOU WILL FIND THE CONFERENCE PROGRAMME ONLINE AT WWW.AFRIMOLD.CO.ZA/PROGRAMME.PHP
MOULD BASE SA WE SUPPLY THE FOLLOWING: LKM Wide range of mould bases and mould components, comprehensive range of products Yoke Industrial Specialised lifting points for the moulding industry Suresee Photonics for mould inspection and protection
Ron MacLarty, organiser of AfriMold, flanked by Victor Stiehler of Hestico and Dave Moore of Mould Base SA who also attended the AfriMold briefing
Dave Moore: 083 675 8325 Fax: 086 540 0908 | Email: mouldbasesa@gmail.com Physical address: 10 North Park, North Street, Pietermaritzburg
PHOTO: LOWRIE SHARP
Official South African Representative for the LUNG KEE GROUP
INDUSTRY NEWS
The configuration of the new Performance plant at Beaconvale in Cape Town is the result of years of experience gained by the team in the production of colour masterbatch – and the layout allows for further expansion and optimum product flow. Lab technician Sam Magape has moved to the Cape from the Performance plant in Meadowdale
Andre Nieuwenhuys setting up the lab film line; samples are used to perform colour strength tests
Brett Pollard and Shane Russell are now also familiar with fire safety drills
Riccardo di Blasio busy doing a colour match for a client. Expansion of the lab now enables Performance to match customer colour requirements and conduct tests with far quicker turnaround times
PHOTOS: MARTIN WELLS
Performance Colour Boosts supply with Cape expansion Automated colour paste dispensing system generates virtually zero scrap
20 OCTOBER / NOVEMBER 2012
PERFORMANCE Colour Systems has expanded its service in the Western Cape by moving to larger premises, installing additional extrusion capacity, and introducing an automated colour paste dispensing system, continuing the group’s drive to be a ‘world class’ manufacturer. The cumulative result is quicker turnaround times for all the colour materials Performance supplies to Cape customers … and, with some of the specialities, service to customers nationally will be enhanced too. With certain export markets also being supplied out of Cape Town, the growth into new technology has been a must-do for the Exco team. The new site in Beaconvale is approximately three times the size of the premises used previously in Montague Gardens. Facilities at the lab have been All manufactured materials go direct through to QC
extended too, with the installation of a new ‘Minijet’ injection moulding machine to manufacture test samples. But the most impressive feature of the plant is the new automated paste dispensing system. Utilizing the latest automatic dosing technology, the British-built system manufactures colour concentrates rapidly and cleanly. The colour pastes are used particularly in coatings, specifically for PVC sheet, as well as in polystyrene, polyolefin and polyurethane mouldings – all popular sectors in the Cape. The advantage of the system is its automated ability to manufacture even small orders – of 25 litres (or less), for example – with virtually zero scrap. Expansion of the lab now enables Performance Colour Systems to match customer colour requirements and conduct tests with far quicker turnaround times: a lot of the testing and matching work was previously done at the Performance plant
Riccardo di Blasio and the new mini test injection moulding machine
in Meadowdale, Johannesburg, but results for samples from convertors in the Cape are now available within hours. A test film extruder is used to test colour strength, an advantage being that the line can be started within minutes. One of the first observations drawn as a result of the upped testing activity at the enhanced lab, according to new Performance branch manager Riccardo di Blasio, is that weather conditions during the colder and wetter Cape winters affect closures differently: closures manufactured during winter months tend to swell slightly, in some cases beyond tolerances. The process of finding a solution to this occurrence is already underway. The technical ability of the Performance team really does stand out, and they are well on their way to being ‘world class’ and meeting their objectives. www.performance.co.za
The new colour paste dispensing system is catering for PVC sheet and PU convertors in the Cape region.
INDUSTRY NEWS
LEFT: Anton Tjabring of Plasticomp with the refurbished pulverising line, which he assembled himself. The system is in fact the result of several years of experience, achieving a balance between variables such as blade settings and wear, temperature and throughput rate to yield powders with consistent textures BELOW: Shepstone Rumo and Philip Mkhwane are the machine operators at Plasticomp
Plasticomp increases pulverising capacity PLASTICOMP of Boksburg, now in its sixth year of operation, has achieved a significant increase in pulverising capacity with the commissioning recently of its second line. Plasticomp specialises in the pulverization and size-reduction of PVC materials as well as HD, LD and linear-low polyethylene materials into powders. It also offers a toll granulation service. The company’s main markets are the PVC converting and rotational moulding sectors, but it can on request pulverize
virtually any polymer or rubber material – it has even reprocessed Neoprene rubber material into powder form. It takes the materials down to as fine as 500 micron particle size. Plasticomp was started by Anton Tjabring, who saw an opportunity in the market for a specialised toll granulation/ pulverising operation and started the company in September 2006. Tjabring was previously in the pipe manufacturing sector. Now he’s using knowledge gained in the use of PVC powders in pipe extru-
sion to good effect. This is an advantage as, quite literally, not all powders are the same. Converters require a high level of consistency of particle size and good material flow, to allow for better dispersion in the subsequent reheating phase. Plasticomp also specialises in relatively short runs. • PLASTICOMP, PHONE 011 918 3412 www.plasticomp.co.za
Polymer resin manhole covers
reduce the risk of theft A lightweight and durable range of nmc polymer resin manhole covers AVAILABLE locally through Incledon, provide engineering contractors and municipalities with a cost-effective and reliable alternative to industry-standard cast iron. Incledon national product manager for civils, Kelly Wilson points out that Incledon is a distributor of the polymer resin products, which have been manufactured locally since 1992 by Cape Town based National Manhole Covers (NMC). “NMC manhole covers are manufactured from a composite material that is bound together by resin and fibreglass, which has no scrap value whatsoever. This material can prove to be invaluable for local municipalities, as the biggest challenge with traditional cast iron manhole covers is the fact that they can be sold for up to R500 at local scrap dealers,” 22 OCTOBER / NOVEMBER 2012
he explained. NMC polymer resin manhole covers are compliant with SANS 1882 2003 specifications, which were established to recognise the need for an alternative material to cast iron and concrete. According to the minimum criteria set by the SABS, a heavy-duty polymer concrete manhole cover should be able to withstand a load of up to 13 500 kg. This minimum weight surpasses the maximum wheel load required and enforced by the National Department of Transport. The manhole covers are ideally suited to telecommunications companies as they come standard with an interchangeable locking device, which ensures that valuable cables beneath the cover are also protected from theft.
NMC polymer resin manhole covers are compliant with SANS 1882 2003 specifications, which were established to recognise the need for an alternative material to cast iron and concrete
www.incledon.co.za
SCINERGY CHEMICALS
shows rapid growth BY JODIE DAVIE ES-COLEMAN N
IN THE few short months since establishing their additives supply company, partners Kumar Naidu and Nico Scheepers have brought four new plastics principals to the South African market and formalised the local presence of two more. Their secret? A synergy – a combination of elements that produce an effect greater than the individual parts – that is best spelt as Scinergy. With 19 years’ technical experience in the PVC industry, technical director Kumar delivers the science of Scinergy, while managing director Nico’s strong foundation in chemical trading and general commerce delivers its energy. Combined, the team has the beginnings of an extensive product range for the SA market from established international suppliers. Instrumental to Scinergy’s rapid growth is international additives company, Baerlocher GmbH. Baerlocher, one of the global greats in PVC stabilisation technology, has been eager to expand its South
African market and looked to Kumar and Nico’s combined experience within the local plastics industry to make this happen. Having now formalised a long-term exclusive agreement for Southern Africa, the Baerlocher/Scinergy venture is setting out to achieve its objectives in a structured and responsible manner. Representatives of Baerlocher recently visited South Africa to further cement relationships and to visit a number of key customers in the various regions. Since officially opening for business on 1 March, Scinergy has also achieved exclusive representation rights for KLJ Organics LTD – a joint venture company owned by Qatar Industrial Manufacturing Co. (QIMC) of Qatar and KLJ Organic Ltd. of India. Similar to Baerlocher, Scinergy has helped to formalise and strengthen KLJ Organic’s fragmented representation in South Africa to date. KLJ Organics is the largest Indian manufacturer of commodity and speciality plasticizers and chlorinated
Scinergy’s Nico Scheepers and Kumar Naidu with Angelique Wilson and Belinda Goosen
paraffins. Scinergy has also been awarded the sole agency of four new companies to the local market: Lestar Chemie (Argentina), Indofil (India, part of the K.K. Modi Group), Anadolu (Turkey) and Sundow Polymer Co. (China). While the PVC converting industry remains Scinergy’s core business focus for the time being, Nico and Kumar hope to expand into parallel industries at a later stage and create a truly unique specialty additives supply company, centered on small volume, high margin products. www.scinergy.co.za OCTOBER / NOVEMBER 2012 23
Computer Aided Design
Computer Aided Machining
Computer Aided Engineering
NX 8 for Design. Smarter Decisions, Better Products
ASSOCIATION NEWS BY SUE CHARLTO ON
Increased popularity of conference among engineers and specifiers suggests SAPPMA strategy is reaping results FOR the sixth consecutive year, the Southern African Plastic Pipe Manufacturers Association pulled off yet another successful conference with nearly 200 delegates filing into the Bytes Conference Centre in Midrand in September. With a great line-up of speakers, papers, exhibits and tea-time interactions, no-one was left out of the plastic hoop – it could be described as the ‘great moulding’ of plastic pipe professionals!
PIPE 2012 The panel discussion at the culmination of the conference, introduced last year, has become a positive way in which to end the day
SAPPMA has over the last few years embarked on a marketing campaign to encoureconomic situation within the mining sector, age specifiers of plastic pipe to attend its but highlighted recent developments on annual conference, and the success of this the acid mine drainage (AMD) issue which effort by SAPPMA is evident by the increase would have an impact upon the plastic pipe in civil engineers and other key engineering manufacturing industry. professionals that are now attending this “The AMD situation now seems to have event. returned to the hands of the technocrats In his opening address, SAPPMA chief who are busy establishing what options are executive officer Jan Venter welcomed likely to offer a constructive solution now that delegates and tracked the origins of plastic the issue has become depoliticised. The pipe, leading up the observation that the problems at hand in terms of AMD are: brine industry has become management, the an indispensible eleoverall business case ‘Humble pipe’ is an ment of infrastructure in terms of who pays essential player in quest to development: 18 million for the clean-up and meet ‘triple challenge’ tonnes of plastic pipe the HDS holding faciliwill be manufactured in 2012, equating to 18 ties which are large and costly. Rand Water billion metres of plastic pipe! The plastic pipe is currently involved in the development of a manufacturing sector is expected to grow at new risk assessment methodology regarding an average of 7% through to 2020. the risk to infrastructure from AMD plumes, as the extent of the risk is more wide-spread Kick-Off session than thought,” said Turton. He encouraged The keynote speaker was tell-it-like-it-is delegates to touch base with the Rand Water Dr Anthony Turton, whose presentation group as he felt their new think-tank could ‘Post-Marikana Prospects for the Pipe Inoffer insights. dustry’ focussed on the current political and Turton flagged up additional factors 1
1. Keynote speaker Dr Anthony Turton, SAPPMA CEO Jan Venter and Peter Kleynhans, president elect SA Institute of Civil Engineers
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that have implications for the industry “Infrastructure spend as envisaged in the New Growth Path is probably going to be severely curtailed as the ‘post-Marikana’ economy teeters; recycling will only come of age when our economy starts to recover, the ‘New water’ concept is something to watch as it embraces dual stream reticulation, aquifer storage and recovery and management of evaporative losses. I also envisage a migration of water intensive industries down to coastal areas over time” he said. ‘The Humble Pipe and the Triple Challenge’ With the increasing number of civil engineers attending the SAPPMA conference, it was apt for the president-elect of the SA Institution of Civil Engineering, Peter Kleynhans to discuss the government’s socio-economic ‘triple challenge’ and the role of our “ever-living and ever-loving humble pipe”. “The government has identified three socio-economic imperatives as requiring 2
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2. Barend Jacobsz, Schalk de Klerk and Jason Tannous of Marley on their company’s stand, which was adjudged the top exhibitor at Pipe2012; and (right) Bevan Richardson was on hand to accept the gold award from Louise Müller of SAPPMA
Dawie Fick, session chairman and also chairman of the IFPA group, thanked Mike Smart for his presentation; Smart in turn encouraged delegates to photograph this display … and remember it!
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3. What’s in the pipeline? Michael Pretorius of Hydrodifusion, on the company’s stand
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4. Renier Snyman of DPI, who also gave a presentation about the process leading up to lead-free production, on his group’s stand at Pipe 2012
ing this triple challenge” he concluded. The Long and Winding Road The road to lead-free stabilisers has been long, its advantages have been well documented over the decades, and while lead stabilisers posed no consumer threat, it is toxic to those in the workplace and in close contact with raw lead and stabilisers. Renier Snyman of DPI Plastics said: “In addition to the risks involved for workers being exposed to the raw lead, lead stabilisers were found not to be compatible with certain stabilisers and additives. Also, PVC was beginning to receive some bad publicity due to the lead content. In 2003, South African local manufacturers started experimenting with different stabilisers, and SAPPMA was invited to oversee this process. South Africa was manufacturing lead-free plastic piping by 2010, exceeding European regulations. “Of course with the advent of green issues, and the drive by the Green Building Council of South Africa (GBCSA) to ensure that products and technology used in the industry conform to their requirements, SAPPMA lobbied the GBCSA to not exclude plastic pipe, so with the advent of the leadfree plastic pipe, we managed to remain inclusive and comfortably conforming with GBCSA standards. Anyway lead technology is old technology – time to move ahead,” added Snyman. SAPPMA has drafted its own environmental policy and all members of SAPPMA are required to conform to lead-free pipe production as a requirement of membership. 5
5. Dawie Fick of Customized Plastic Products with Misheck Mumba and Willie Katebe of Wheals Construction, all the way from Kitwe, Zambia. 25
PHOTOS: LOWRIE SHARP
particular attention, namely: poverty alleviation; removal of inequality and a reduction in unemployment – these are collectively referred to as the triple challenge,” said Kleynhans. He put forward the view that a sound, well-balanced socio-economic regime is the foundation of efforts to address the triple challenge and that all economic activity and social services require the efficient and effective conveyance of fluids – the humble pipe is therefore an essential player – and the benefits of pipe must be maximised and the liabilities minimised. Kleynhans pointed out that crucial steps are needed in the quest to meet the triple challenge, namely: The materials and manufacturing processes: a balance is required between extractors and processors of raw materials and pipe manufacturers with factors such as energy needs, quality of product and employment of labour, while keeping the industry competitive locally and internationally; Planning, design and documentation: the identification, selection and design of
appropriate pipes for specific service delivery requirements need to have sound bid and contract documentation attached. The ability to identify leaks that might occur during the operating life of the installation is important in alleviating potential financial wastage which could be directed elsewhere. Labour-based methods of construction for pipelines and pipe systems contribute to poverty alleviation and a reduction in unemployment; Construction, testing and commissioning: how the pipe and its associated fittings is constructed, tested and installed will determine its high or low lifelong liability, factors which can reduce the lifelong liability will enhance the contribution to addressing the triple challenge; Management, operation and maintenance: pipe installations should be fit for purpose, the absence of sound pipe management results in unnecessary maintenance and/or replacement costs. The very points that Kleynhans advocates are essential to meeting triple challenge criteria are not without their own ‘tensions,’ as he calls them. For example, if one limits expenditure on pipe installations to release funds for more direct measures of addressing the triple challenge, you often curtail local employment. “The manner in which we approach and execute our disparate roles in the life-cycle of pipe installations either contributes to the country’s ability to address the triple challenge or detracts from it. By fulfilling our obligations as pipe practitioners with due skill, care and diligence, we contribute to address-
ASSOCIATION NEWS
How important is it that plastic pipe standards are stipulated for the application under tender? Kleynhans: Inadequacy in the bid documents and procurement process can result in inappropriate tenders being awarded to inappropriate contractors, placing the quality of the constructed asset at risk. Most well-structured contracts call for materials to be manufactured to recognized standards and it would be beneficial for manufacturing associations to endeavour to ensure that this is universally the case. The more traditional contract form is ‘supply and lay’. In these contracts, a contractor has to provide and install the pipes. The contractor is free to select a pipe manufacturer and a pipe supplier provided the pipes comply with the specification in the contract document. If the contract is not clear on the pipe specification and the need for a recognized standard mark, there is a risk that inferior piping could be used. The manufacturers’ association can also add value by inspecting the bid documents and alerting the ‘engineer’ to any shortcomings prior to bids closing so that notices can be sent to bidders during the tender period clarifying relevant portions of specifications as well as the need for pipes to comply with a recognized standard. The manufacturers’ association can also assist site staff by ensuring the pipes are to specification and in sound condition when delivered to site, as well as helping site staff check the pipes are well laid and protected.
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6. Dr Ron Watermeyer of consulting engineers Soderlund & Schutte, who gave a presentation about the sinkhole formation phenomena in dolomitic land, with session chairman Dawie Fick 26
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Dolomite dangers can be avoided According to Dr Ron Watermeyer and his team at consulting engineers Soderlund & Schutte, between three and four million people are living or working on dolomite land in South Africa. Dolomite is susceptible to sinkhole activity due to leaking water-bearing services; poorly managed surface water drainage and groundwater level drawdown. A recent risk management system research project on 3700ha of urbanised environment on state-owned dolomite land south of Pretoria produced a result of 650 sinkhole manifestations from 1984 to 2004 when no risk mitigation measures were in place. “There are strategies to assist in reducing the number of incidents occurring in areas that are at risk, such as placing restrictions on land use; ensuring there is appropriate development; establishing requirements for installation of below ground infrastructure particularly water-bearing services; the construction of above ground water bearing structures; building design as well as the maintenance and management of surface drainage and dewatering and water-bearing structures and services,” said Watermeyer. A broad range of pipes including water and sewer pipelines threw up issues such as leaks at pipe joints, unprotected pipes corroding in aggressive soils, age, uPVC pipes poorly joined or placed on poorly compacted backfill and poor workmanship were reported as of concern in dolomite areas. Sinkholes typically occurred where stormwater pipes were on lined and unlined canals and drainage ditches; concrete pipelines, on lined canals where the joints were not sealed appropriately, prefabricated canals that were not placed on compacted bases, areas of poor maintenance
and where storm water was discharged directly into the ground near foundations. “In essence, the solution seems quite clear, link land use and infrastructure types to dolomite land designations. Wet services which include pipelines of various functions should entertain considerations such as keeping the number of joints to a minimum, look ahead to future connection requirements, sloping of trenches away from buildings and minimise maintenance requirements and any potential leakage points as far as possible. The selection of pipes and fittings is crucial to environmental and application requirements”. “Proper water management and dolomite control can reduce hazardous events by up to a factor of 10 – it is not rocket science, it is common sense,” he added. PIPE2012 SNIPPETS Andrew Wedgner of Borouge in ‘New solutions for large-diameter industrial water pipes’ concluded: The highly durable nature of PE and PP-HM pipes makes them suitable for large diameter industrial water pipelines providing pressures are not too high. PE100 and PP-HM pipe grade materials are now readily available in the Middle East. Dr Mark Webb of SSIS Pipeline Services, in ‘Soil Behaviour, Pipe Behaviour and Soil-Pipe Interaction,’ gave general tips on pipe laying and jointing. Alaster Goyns of Pipes cc, in ‘Pragmatic Approach to Structural Selection of Gravity Pipelines,’ said “The backlog in the demand for pipelines to supply all South Africa’s citizens with clean water and take away their waste water means that attention must be given to the construction of new pipelines as well as the rehabilitation of existing ones.” Steve Tan of PVC4Pipes of Brussels, in ‘Oriented PVC Pipes (PVC-O)’, said Molecular orientation of PVC provides pipes with outstanding properties, including high strength; excellent impact resistance; good resistance to surge and fatigue; increase hydraulic capacity; lower pumping costs; good environmental credentials; PVC-O – is the system of choice for drinking water applications.
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7. Parattakorn Jirathiyut and Attawut Kumkrong of SCG Chemicals of Thailand (Attawut also gave a presentation) with Ahmet Abulaziz of Manuchar South Africa
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8. George Diliyannis (session chairman) thanked Joe Majorobela of Sasol Polymers for his presentation
9. Frank Makamo of the SABS, Dawie Fick (session chairman), Andrew Wedgner of Borouge and Simon Scruton of eThekwini Municipality (KZN)
PHOTOS: LOWRIE SHARP
Q&A with Peter Kleynhans
Snyman went on to say that alternatives to lead include calcium/zinc stabilisers, which has been used in PVC applications for over 25 years and is regarded as nontoxic, but has a narrow processing window; and organic-based stabilisers which were developed some 15 years ago and offer a wide processing window.
ecoSTAB
TM
LEAD-FREE STABILISERS Tomorrow’s PVC Solutions Today from Sun Ace
ASSOCIATION NEWS
Q&A with Dr Anthony Turton What opportunities exist in the plastic pipe sector in terms of AMD? Dr Turton: There is significant potential for plastic piping as hazard and risk assessment methodology improves, most notably in the area of acid mine drainage (AMD). Preliminary results suggest that all metal-related infrastructure could be at risk where AMD plumes are found. The replacement of such infrastructure is probable as are changes to the cathodic protection for infrastructure left in situ. One option might be the use of plastic piping. One unknown factor that would need to be researched is how plastics would respond to potentially elevated levels of radionuclides that might be associated with certain AMD plumes.
Upcycling … from banner to bag THE conference bags at SAPPMA’s Pipe2012 event were colourful, light, comfortable ... and unusual! The bags are made out of recycled PVC banners, with a polyester mesh on the inner/middle layer, and then ‘upcycled’ into conference bags by the Recycling Box Company. Pushed into action by Delanie Bezuidenhout CEO of the SA Vinyls Association, Lisa Kuhle of Recyling Box Company said: “SAVA challenged me to use PVC as a fabric as an alternative to the virgin fabric that was being used at the time. The stitching is polyester and the binding is polypropylene. We have enabled 36 informal jobs as a result of ‘upcycling’ old banners and the likes through the use of PVC across a range of promotional materials. In fact, we have just won an award for a geyser blanket that is bound with upcycled mesh from old Telkom billboards”.
SAPPMA AGM HIGHLIGHTS
What positive socio-economic impact can the plastic pipe sector make?
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OCTOBER / NOVEMBER 2012
Jan Venter (Chairman of SAPPMA), Louise Muller (SAPPMA), Hein Momberg, Tony Dean, Louis Albertyn and Gerhard Kotzee (Absent: Andre Botha)
SAPPMA held its 8th Annual General Meeting on 22 August at the Bytes Conference Centre in Midrand. The conference was well attended by SAPPMA members, along with members of the media and other role players involved in the manufacturing of plastic pipes in South Africa. Guest speaker Merina Willemse, an economist at the Efficient Group, said that although the South African economic growth percentage is very low at 2.7%, the cycle is slowly getting rid of unproductive businesses and this should have a healthy effect on the economy in the long run. Focusing on the role and importance of the plastics industry in SA, she emphasised the important role of manufacturing in the economy and said that the forecast for the next year was looking much better for this sector. However, due to increased pressure on the manufacturing industry, productivity must improve and prices will be forced
lower. “This is the kind of stimulation our country needs, along with an increased flow of funds into the country by means of trade and financing”. SAPPMA board members for the year remain unchanged: Jan Venter (Chairman), Gerhard Kotzee (DPI Plastics), Hein Momberg (Fiberpipe), Louis Albertyn (Marley Pipe Systems), Tony Dean (Flotek) and André Botha (Sasol). SAPPMA Chairman Jan Venter also welcomed a new category of SAPPMA affiliated membership, Pipe Dealers. “We are proud to introduce three pipe dealers, Water Africa, Sizabantu Piping Systems and Astore Africa to this new category which has allowed us to take an important step towards covering and including the whole value chain in plastic pipe manufacturing and installation”, Venter said.
Matter of fact The article “Heavy metal free!” on page 36 of our August/September issue, about locally manufactured plastic pipes being lead-free, used a photo of black HDPE pipes to illustrate the article. The article in fact only applied to PVC pipes. Our apologies.
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
PHOTOS: LOWRIE SHARP
Dr Turton: Mining will probably become a partner for regional development with a broader range of benefits distributed across a wider range of beneficiaries. Central to this is the provision of water supply and sanitation, which is of major interest to the plastic piping industry. The emergence of ‘New Water’ initiatives is also an opportunity. New Water is the improvement of yield via the management of reticulation systems, return flows and a reduction in evaporative losses. Elements of this will include a ‘dual stream reticulation’ economy where water of different qualities and costs will be used for different purposes. This will need different grades of plastic piping, with different standards that might not exist at present (e.g. standards for the management of grey water). Another opportunity will arise from the emergence of ‘Managed Aquifer Recharge’ or ‘Aquifer Storage and Recovery’. This increases yield by reducing losses to evaporation as water is stored in underground aquifers rather than in open dams. If this becomes mainstream technology in SA, then the plastic piping industry will need to develop specific solutions such as sub-surface manifolds capable of operating over long time scales without being crushed by backfill.
SAFRIPOL
celebrates 40 years One of the biggest success stories of the SA polymer industry to date
INDUSTRY NEWS
SAFRIPOL, a name which is synonymous with the development of the South African polymer industry, celebrates 40 years of operation this year. Originally established in 1969 as a 50:50 joint venture between Sentrachem and Hoechst of Germany, then the largest chemical company in the world, Safripol actually traces its origins to the date of commencement of material supply, which was 1972, when it started supplying highdensity polyethylene to the SA market. Production of polypropylene at the Sasolburg plant, and supply to the market, commenced two years later in 1974. Those early years were challenging for the business: although it had the support and active participation of its then parent, Hoechst group, polymer production skills within South Africa were in their adolescence at the time. Hoechst was the preeminent player in the global polyolefins market then: prior to the SA venture it had set up polymer production plants in India, Australia, Brazil and the USA. The creation of Safripol hence placed South Africa in elevated company, and also identified it as one of only a few polymer producers in Africa. Hoechst and local partner Sentrachem actively set about developing individuals with the requisite polymer production expertise and skills. The company ethos was always based on strong customer focus as international experience demonstrated that customer loyalty can only be achieved through superior quality and service. The timing of the establishment of 30 OCTOBER / NOVEMBER 2012
Safripol turned out to be fortuitous: the world’s first oil crisis occurred a year later in 1973, when the Arab members of OPEC (Organisation of Petroleum Exporting Countries) declared an oil embargo. The result of this was spiralling fuel costs and, as a direct consequence, rapidly increasing polymer prices. South Africa would at the time have been a distant satellite to the global oil crisis, but the challenges for the fledgling Safripol operation were sizeable nonetheless. Capacity in the 1970s was in the order of 40 000 tons per annum of HDPE and 30-35 000 tpa of PP. Although Safripol had an agreement with Sasol to obtain the feedstock from the latter’s petrochemical plants at Sasolburg and Secunda, any production interruptions at these plants could affect Safripol’s production – and directly impact
its customers. Such a scenario did occur in 1984, when propylene supply was interrupted. The result of this was the construction by Safripol of a massive 4 000-ton storage tank for propylene at Richard’s Bay on the KZN coast, a further major investment. Quantities of propylene were also secured with the installation of a splitter at the SAPREF in Durban. Safripol’s arrangement with Sasol to secure feedstock was to come under the scrutiny of the Competition Commission much later, when the merger of Sasol and AECI’s polymer businesses potentially limited the competitive environment in South Africa. In 1996/97 a further major investment was made when a new PP plant was constructed at Sasolburg. The old PP plant was then rebuilt into the third HDPE ‘train’. The HD plant was completely refurbished at the same time too.
On-going improvement – Pictured here, Safripol’s HDPE plant. Safripol’s HD and PP plants at Sasolburg have been upgraded, debottlenecked and modernized consistently over the past four decades. A wholly new PP plant was constructed in 1996/97, at which time the old PP plant was rebuilt into the third HDPE ‘train’; the HD plant was completely refurbished at the same time too
Support for customers – The main warehouse at Sasolburg, where sizeable stock levels are maintained to ensure on-going supply to convertors in South Africa as well as around southern Africa
Global technology – The quality of polymer produced is a main criteria for convertors and Safripol has through its technology exchanges with, originally, Hoechst group and since then with Dow, LyondellBasell and Qenos succeeded in producing consistently high quality HD and PP pellets across a range of grades
Capacity increased alliances. From the beginning, Safripol formalized alliances with Dow and with LyCapacity was increased sequentially, with the improved skills of the Safripol production ondellBasell, the largest plastic companies in the world. team, to the point that output had reached Incidentally, LayondellBasell is now the 160 000 tpa for HDPE and 120 000 tpa holding of all the original Hoechst and Monof PP by the beginning of this millennia. tell technologies which were originally used Safripol had become a big player in the for starting Safripol. Another LyondelllBasell African context, the Hoechst group was ex-Hoechst company, Qenos in Australia, transforming and the new South Africa was was also added to the technology alliances attracting new investors, and so the operaas it had developed tion attracted the interto become one of est of international In one of the biggest ever the original pioneers group Dow Chemical transactions in the SA of high-pressure Company, which in plastics industry, the HDPE pipe materials 1997 purchased Senproduced in the same trachem group, and R1.3-billion MBO took type of factory as hence Sentrachem’s place in 2006 and the Safripol’s. share of Safripol. Two Safripol name was revived But, more than years later, in 1999, anything else, the Hoechst ‘unbundled’, revival of the Safripol name helped clearly resulting in it selling its share to Dow. identify the business’s role and its identity. Safripol hence rebranded and operated as The transaction was consummated, so to Dow Plastics SA. speak, when Safripol succeeded in partnerThat spelt, for a time, the disappearance ing with black empowerment partner Thebe of the Safripol name, but it wasn’t forgotInvestment Corporation, which acquired ten. A number of the individuals concerned a 21% share of Safripol; together with the maintained the vision, however, and when Dow in 2006 made clear that its geographi- other shareholder’s, Safripol’s BEE ownercal focus was changing, a local team involv- ship is 26%. ing Joaquin Schoch, Geoff Gaywood and Bernhard Mahl led the charge to regain SA Highlights ownership of the business. The company mission, vision and values In one of the biggest ever transactions had to be built around the customer focus in the SA plastics industry, the R1.3-billion and the partnership and respect for the MBO took place in 2006. The Safripol name many people involved at all levels in busiwas revived and with it, the continuation of ness. Dedication and technology had to Safripol’s legendary customer service was result in also excelling in Safety, Health, reassured. Environmental and Quality (SHEQ) policies, Although it may have retained its original practices and ratings. In fact, Safripol is one character, the business was now sans its of the few companies in South Africa which international partners, but that allowed more has managed full years with no reportable flexibility in choosing the best technology SHEQ events at all and usually yearly rat-
ings are well below the industry’s average. Safripol is very aware that people are the core for excellence in performance, quality and reliability, and it is people who make business a success. It was this basic belief that motivated Safripol to participate annually in the Best Employers Awards survey, where they have always ended as a finalist and often on the podium of South African employers. Among the more recent highlights for Safripol was the introduction in 2010 of its iMPACT 100 high-pressure pipe grade material. Working in cooperation with Qenos, this new generation PE100+ pipe material was first produced in Sasolburg in October 2009 and introduced to the market the following year. The high standards for this material grade, which is tested and viewed as second to none in global standards, are due to the need for the manufactured pipe to perform for a minimum of 50 years – under pressure. Today Safripol employs approximately 250 people at Sasolburg and its head office at Bryanston. Its management team consists of CEO Schoch, chief operating officer Gaywood, commercial director Mahl, financial director Frans van Dyk, production director Nico van Niekerk, site director Charles van der Walt, and public affairs director Ian Kennon. The strategy adopted then, with Safripol developing and manufacturing for direct sales to the larger converters around the country and the Plastomark group being its national ex-stock distributor, continues in operation in what remains one of the biggest success stories of the SA polymer industry to date. www.safripol.co.za
A polymer plant never sleeps! – The simple fact about producing polymers is that the goal is to cease production only for planned maintenance shutdowns, so the plant will be running 24/7 for virtually entire years. One of Safripol’s strengths over the past four decades has been the high level of team work achieved by the production teams at Sasolburg OCTOBER / NOVEMBER 2012 31
ASSOCIATION NEWS
Rotation 2012 Energy savings and ‘back to basics’ highlighted at ARMSA bosberaad ROTATIONAL moulders from around Southern Africa and further afield gathered for what has become their annual bosberaad, the ARMSA ‘Rotation 2012’ conference, at Zebula estate at Bela Bela in the Waterberg in September. The quest for roto moulders, that of manufacturing products more rapidly and cost-effectively, remains unchanged. Over the years the focus at the ARMSA Rotation events has been on technology advances, whereas the thrust this year was on sustainable and ‘green’ production. Energy remains a major cost for roto product manufacturers and several of the speakers dwelt on that area. Game drives were hardly necessary during the 5-7 September event, since a herd of rare sable antelope appeared to have taken up residence on the adjacent golf
course, and the master of card tricks and Where does my heat go? chief fundraiser, Rod Cairns of JoJo, was The show kicked off with a presentation by his usual unrelenting self. Nico Hickley of CHM Plastics, winner of last One of the standout presentations at year’s ‘Product of the Year’ competition, on this year’s conference was that by the the problem of heat. Heat is obviously a evergreen Gary Lategan of Roto Solutions. major factor for roto moulders, for practical Gary has been a consistent phenomena as well as, obviously, cost reasons. Nico at the Rotation events over the years, and preempted his conclusion by stating at the his enthusiasm to discuss any and every outset that heat seems to go “everywhere aspect of roto production has – compared except to the polymer” – and that can often to other industry appear to be the case Consumption figures show sector shows in Africa in the roto industry. roto industry is continuing – provided a unique But it is invariably opportunity for roto difficult to achieve an with steady growth moulders. This year ideal result in a situaGary took delegates by surprise, however: tion where heat is applied, as inefficiencies not only was he not discussing temperature are common in industrial applications in general. CHM has on average been using control, he suggested that rather than look 0.43 litres of paraffin (or the equivalent in for ‘new’ solutions, roto moulders “go back another fuel) to process a kg of polymer, to basics” and focus on the fundamentals leading Nico to the observation that heat of the process. Fundamentals like making efficiency in the roto business could be as sure production staff actually understand the process. We review Gary’s presentation low as 3-5%. This observation was drawn from heat below.
The cause … and the result
21st National Rubber Conference 2013 Hosted by The Institute of Materials, Minerals and Mining Polymer Division, Southern Africa Division Venue: Cape St Francis Resort and Conference Centre Cape St Francis, Eastern Cape, South Africa Date: Friday 8 March to Sunday 10 March 2013
Contribution to charity – Try and avoid this … and you’ll pay. Actually, you’ll pay anyway. Rod Cairns of JoJo was at his humorous best as the auctioneer at Rotation 2012. The aim was to raise funds for this year’s charity of choice, Ikaya Nothando Place of Safety for Infants, a home for abandoned or rescued toddlers in Pretoria. The result: as can be seen in the hands of a happy Anle van Niekerk, R3500 was raised. This positive outcome was were very much the result of the ceaseless banter by Cairns – with him you have no chance of avoiding immediate payment, ever. Ikaya Nothando provides a home with nursing and education for the youngsters, so thank you to all the ARMSA members and delegates for your contributions.
Call for Papers close Friday 30 November 2012 Delegate registration closes Thursday 7 February 2013 For more information contact Wendy Knott-Craig: wknottcraig@vodamail.co.za Sasol Polymers team – Sasol Polymers has been consistent in its support of the ARMSA Rotation conferences over the years. Mike Meyer, Jaco Scheepers, Giel van Jaarsveld, David Skosana, Brian Sole and Nick Aggett attended this year’s event at the Zebula estate at Bela Bela in the Waterberg 32 OCTOBER / NOVEMBER 2012
Roto polymer consumption Next up, outgoing ARMSA chairman Clive Robertson gave a presentation on ‘Year on Year Roto Moulding Polymer Consumption’ in Southern Africa. Consumption by roto companies has increased from about 8000 tons a year in 1996 to close to 30,000 tpa in 2012, which is very positive trend for the sector. His figures also indicate that the sector has recovered well
from the bleak economic period of 2009. That year consumption declined by 4.6%. There’s been a steady increase since, with 2011 being an exceptional year with a 13.5% increase in consumption to 26,600 tons. 2012 is expected to show an increase of about 6 percent, to an estimated 28,180 tons, which is a positive result Taking the heat – Clive Robertson introduced first speaker Nico Hickley, in the present economic who’s talk concentrated on the problem of heat dissipation in the roto climate. process – it “goes everywhere except into the polymer” said Nico. Nico also, at very short notice, manufactured the new trophy ARMSA ‘Product Clive, who has been of the Year’ floating trophy in the foreground involved in roto moulding almost from the sec‘Get Greener with Simple but tor’s outset in SA, provided an interesting smart Moulding’ chronology of roto highlights over the past Roto Solutions’ Gary Lategan is by now almost two decades. Given that the first new large certainly one of the most widely travelled roto roto machine only arrived in South Africa expert internationally, ever. The man has visited in 2005, one can see how the business’s over 400 roto companies in 66 countries on all growth is gathering momentum. five continents, as a result of which there are few Clive also gave a presentation about who know rotational moulding better. the formation of his new company, ACD Up till now Gary has dwelt mainly on Roto Rotoflo, which set up shop in Kya Sand, Solutions’ TempLogger temperature control Johannesburg, earlier this year. The estabsystem, but now he’s focusing more on “getting lishment of the business marks the entry of back to basics”. only the fourth ever dedicated roto powder He has noticed that “at least 90% of all mouldand colour compounding operation in ers I visit have the same basic problems,” said South Africa. OCTOBER / NOVEMBER 2012 33
PHOTOS: LOWRIE SHARP
losses in the burner, the oven and due to the need for reheating, which could constitute as high as 90% of the input heat. When you consider that the heating of aluminum or steel in moulds is a major cost, you can see why mould designers seek to eliminate any unnecessary metal from moulds. Nico illustrated his point with a test comparing a 9kg cast aluminum mould with 8mm wall thickness and a 6kg CNC machined mould with a 5mm wall thickness, where the lighter mould saved significant fuel costs. Obviously you can’t simply lightweight all moulds, but need rather to achieving an optimum weight, but unnecessary metal is definitely unattractive. The observations from his research suggest that avoiding oven cool down, utilizing oven capacity as much as possible and demoulding “as hot and fast as possible” are the most practical options.
ASSOCIATION NEWS
Product of the Year winners IN HOT WATER
THE WINNING TEAM
RUNNER-UP
The Jack Wiid Floating Trophy came home in 2012, when it was won by the man who first proposed the concept of the competition. Here we see Jack with the trophy and the Pioneer Plastics team, including Johan van der Westhuizen, Nick Swardt, Gary and Wayne Wiid (with the new roto moulded version of the trophy) and Jim Sepahane – well done guys!
Nick Swardt, technical manager at Pioneer Plastics of Rosslyn, with the ARMSA Product of the Year winning entry, a solar tank roto moulded in polypropylene. A low-pressure water heating system, the tank is intended for domestic use, operating on a gravity basis – as opposed to the higher cost high-pressure tanks. PP, which is not widely used in roto moulding, was selected due to its higher resilience to heat. Black was the obvious choice of colour, intended to increase heat absorption. The mould was developed by researchers at the University of the Free State, but did not function when it arrived at Pioneer. After redevelopment, the Pioneer team succeeded in moulding the complex design. www.pioneerplastics.co.za
HYGIENE CARPET Piet van Niekerk of Accelerate Design with his ‘Hygiene Carpet’ for cleanroom environments, which was runner-up in the Product of Year competition (Pioneer also won the second prize). A complex moulding, the carpet is produced in an EVA-LD mixture, which gives it a rubber-like feel. Its advantage is that people entering food processing or other cleanroom type plants don’t slip on the mat, but it can also be easily washed or hosed down between shifts or whenever necessary. The aluminum mould was designed on CAD and cut on an automated CNC system at Accelerate, the cutting process taking an estimated 140 hours. Piet said the mat was difficult to produce, particularly working with EVA, and he had to come up with some “secret solutions” to get the job out. Accelerate Design, based in Centurion, has been a regular winner in the ARMSA competition over the years – congratulations to Piet and his team! www.accelerate.co.za
make sure operators have a good understanding of the process; good quality material; best grind possible (in which respect the ARMO dry flow funnel test unit is an essential piece of equipment); mould parting lines, vents and frames. The starting point is to MEASURE what is being done on a daily basis and then setting parameters to CONTROL what you wish to achieve.
PHOTOS: LOWRIE SHARP
FIRST PRIZE Gary – and, yes, that applies to the same ratio of the industry in Southern Africa. “There seems to be the perception out there that new ideas will solve the same basic problems,” he added. The most frequently asked questions include ‘How can I reduce weight or material cost to increase profits?’ and to reduce cycle times and labour costs. He feels most manufacturers should could benefit most by having a serious look at their process and training, regarding specifically: 1
1. Welcome back – Old roto hands Jack Wiid (left) of Pioneer and Gary Lategan of Roto Solutions welcomed Keith Chisnall of ACD Rotoflo to the roto ‘family’. Keith, who was originally in the polymer supply business but then joined a wildlife/safari operation, has recently returned to the industry 2. MBT South Africa exhibited on a joint stand with its principal SCG Chemicals of Thailand. Besides supplying high quality roto powders, the Thai team have also
34
Improve product appearance Another previous ‘Product of the Year’ winner, Piet van Niekerk of Accelerate Design, discussed ‘Product Finishing’. Product presentation is obviously an important area for all manufacturing industries, and one ventures to say it’s of paramount importance in the roto sector. 2
3
provided hints of interesting product possibilities, based on their experience in Thailand and other roto markets 3. Nick Aggett (right), who’s been involved with the Sasol Student Design competition since its inception in 2000, received recognition for his unstinting work with his election as an honorary life member of ARMSA; here he receives his certificate from Clive Robertson 4. Your brands have value! – Barry Schutte of Peri
With large moulded products, in which roto manufacturers are rivaled only by composite fabricators, consistent high standard surface finish is often difficult to achieve. His logic may be that it’s better for the industry overall if more manufacturers are achieving high quality surface finishes (as opposed to allowing customer dissatisfaction to grow), but describing his techniques was nevertheless an open-minded gesture on Piet’s part. Piet covered the need to: improve mould flanges (including use of mould release agents on flanges and regular cleaning of the components); improve deburring of parts (he described the tools used at Accelerate); use reference face on trimming knives; and much more. “A lot can still be done to improve the quality of roto moulded products in South Africa,” said Piet. 4
Peri Media of Pretoria gave a presentation titled ‘The Value of your Brand,’ which was surprisingly relevant and important. Roto moulders are often so involved in the technical challenges of producing mouldings that they overlook the commercial values of their products. Barry outlined methods through which you can “ensure that consumers perceive your product properly” and not what you say or feel that it is. He discussed the value of correct and effective marketing
Rotomoulding from Bought a pulveriser ? Need to buy coloured pellets ? We also sell Natural Pellets Natural Powder Colour Compound Powder
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MBT South Africa Unit 14, Eastwood Office Park, 11b Riley Road, Bedfordview. PO Box 751775, Gardenview 2047, South Africa. Tel: 27-11-455 2889 Fax: 27-11-455 2937 www.mbtsa.co.za Rob Wainright Lance vd Merwe Helga Classen
082 801 7373 082 901 0477 083 769 4543
Carlotta Stafford 082 600 7403 Paul Gripper 082 456 6659
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ASSOCIATION NEWS
Sasol Student Design Competition SECOND PRIZE Jomari Budricks of UJ entered the ‘Prosthetic Board,’ a floating device to enable disabled people to swim, which was adjudged as the runner-up
THIRD PRIZE Natalia Tofas’ design of a floating backpack was awarded third prize; she is studying at UJ
FIRST PRIZE
Bronze – Francis Birkenmeier’s chair design was among the top entries
PHOTOS: LOWRIE SHARP
sveld of Sasol PolyNick Aggett and Giel van Jaar of the University ock Bull mers presented Ashton rst prize and certificate of Johannesburg with her fi Design Award for for winning the Sasol Student l lane divider poo ming swim her ‘Coolbeenz’
International speakers As has been the case over the many years during which the ARMSA conferences have been held, Rotation2012 was no exception and the event was again blessed by the presence of two international speakers. Presentations were delivered by Dhanu Patell of Reinhardt Roto Machines of India and Sirinun Mahachassada, technical service manager of SCG Performance Chemicals of Thailand. Patell, who has supplied quite a number of Reinhardt’s machines to African manufacturers, again reassured his commitment towards finding the best and most practical solutions. Conditions in the roto sector vary more than in the other plastics processing technologies, so Reinhardt’s commitment towards finding tailormade solutions is very positive. 5
6
5. Tom Kerpert (right) of DDI Design discussed the many steps (seven main ones) involved in design, development and implementation in industrial design. The most important goal is obviously to achieve an economical feasible outcome for the manufacturer. Presentations such as this are very useful for delegates, who can depart the conference better equipped to deal with challenges; here we see Tom with ARMSA secretary Anle 36
The SCG speaker explained how the roto moulded septic tanks operate. The concept appears to have taken off in the Far East Email: Rotomolding@scg.co.th
Mahachassada discussed SCG’s involvement in the development of rotomoulded septic tanks. The design functions by means of anaerobic decomposition (processes in which microorganism break down biodegradable material in the absence of oxygen). 7
van Niekerk 6. SolidWorks solution – Mecad Systems showed its SolidWorks systems for roto product design, including the demonstration of the design of a tank; Robert Pereira, seen here with Mecad colleague Jonathan Morland, gave a presentation about the process as well as simulated mould construction technology www.mecad.co.za 7. Bryan Kennedy of KRM Plastics of Newcastle, KZN, Heiko Meyer Namibia Roto Moulders of
Given that in any highly urbanized situation, there will be a high need for sewage treatment, and the solution which SCG and its partners have come up with looks to be a winner – over 100,000 of the units from a number of different designers are being manufactured globally a year. 8
9
Okahandja and Paul Krige, also KRM, at Rotation 2012 8. Eco Tanks team – Darren Hanner, Pieter Oosthuizen and Nick Horne of ECO Tanks, East London, enjoyed Rotation 2012 9. Session chairman Wayne Wiid session thanked Sirinun Mahachassada of SCG Chemicals for her presentation about the design, material selection and construction of roto moulded septic tanks www.scg.co.th
The ARMSA committee for 2012/13, elected on the eve of the conference, includes Grant Heroldt (Duys Rotomoulders), Michael Boltau (Lomotek), Anle van Niekerk (secretary), Piet van Niekerk (Accelerate Design), Nick Aggett (Sasol Polymers), Wayne Wiid (Pioneer Plastics, who is the new chairman), Rod Cairns (JoJo Tanks), Peter Lemmer (Calcamite) and Gary Bolt (Atlas Plastics)
COMMENDED Tyler Geldenhys, also of UJ, entered his ‘Transformer Board’ wave board/beach chair in the Student Design competition, which was commended by the judges
Also commended was the ‘Puma Safe’ oating pool alarm system powered by photovoltaic solar panels was submitted by Ricardo Louveiro. Whether the alarm is intended to detect the level of the pool or alert inhabitants of other irregular activity in the vicinity of pools is unclear, but it’s a nice clean design nonetheless
Food contact regulations In an ‘Overview of the Regulatory Landscape for PolyoleďŹ ns Intended to come into Contact with Food,’ MornĂŠ Swart of Sasol Polymers looked at European Union regulations for plastic materials and articles intended to come into contact with food. Considerable research has been conducted in the EU area, and it’s useful for convertors in South Africa to heed these guidelines, not least if you are planning to supply moulded products for food use into the EU zone, but also to follow best health practises in our own region. “Potential health risk may occur from non- or incompletely reacted monomers or other starting substances or from low molecular weight additives which are transferred into food via
migration from the plastic,â€? said Swart. Conclusion One of the salient features of the Rotation event was the high level of attendance by the bigger roto companies, and relative absence of other manufacturers. The obvious observation is that the leading manufacturers are prepared to send delegates, and achieve noticeable beneďŹ ts by involving their staff in a dedicated roto environment. It’s almost certain that every delegate beneďŹ tted in terms of knowledge acquisition. Thanks are due to the sponsors of Rotation 2012: Sasol Polymers, Stuart Polymers, MBT South Africa and ACD Rotoo.
Association of Rotational Moulders of Southern Africa Chairman Wayne Wiid E-mail: wayne@ pioneerplastics.co.za Tel: 012 541 6000 / 082 772 7369
Secretary AnlĂŠ van Niekerk Tel: 082 782 0413 Fax: 012 666 8062 E-mail: anle@accelerate.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
www.armsa.co.za
OCTOBER / NOVEMBER 2012
37
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ASSOCIATION NEWS
Even top manufacturers, retailers now realise we are still learning Better communication could be beneficial for industry
38 OCTOBER / NOVEMBER 2012
THE joint workshop presented by PETCO and POLYCO in August was notable for the fact that, in spite of their best efforts, some of SA’s top convertors and retailers acknowledged that they are still learning about the post-use performance of some of their most popular packaging materials. Workshops on ‘Recyclability by Design’ were hosted by PETCO and POLYCO in Johannesburg and Durban, presenting opportunities for people in the industry as well as other interested parties – specifically retailers and individuals involved in the post-consumer area – to network. Events kicked off with a presentation by Chandru Wadhwani of Extrupet, a very entertaining and insightful speaker. Extrupet’s new ‘Phoenix’ rPET is one of the success stories of the industry at present. The production of food grade rPET is a difficult and costly undertaking, but it’s what global brand owners want now … and the Extrupet team has succeeded in gaining
Extrupet’s Chandru Wadhwani gave very insightful presentations at the workshops in Johannesburg and Cape Town
Cheri Scholtz of PETCO was one of the hosts of the events
all the approvals and steadily upping the output of their plant. Extrupet now finds the entire rPET output from its Wadeville plant is fully committed, and is almost unexpectedly planning an expansion phase. A number of brand owners wanting to include a percentage of recycled material in their packaging have found consumer acceptance of the packs at an all-time high. Combined with the fact that Phoenix rPET is performing as well as virgin material, there is now a trend to increase the ‘r’ percentage in packaging, specifically in this case with rPET. But the path leading up to this has not been easy: Rowan le Roux, sustainability manager at Polyoak, noted in his presentation that they were still learning about some unexpected variables. For example, they had been proposing that labels for PET containers be supplied in PET too – only to realize that this is not what’s required. Labels are often saturated with ink,
which if supplied on a PET substrate will sink in the washing phase during recycling – directly contaminating the quality of rPET yielded. It’s hence more suitable for labels to be produced in a material such as polypropylene (see adjacent caption) which floats. Kiril Dimitrov, packaging manager at Woolworths, outlined how the group’s sustainable packaging ‘journey’ was proving to be unexpectedly challenging. Woolworths is in the process of numbering every packaging item it uses and has succeeded so far in numbering 96% of its goods. Kiril also mentioned that, to date, only one plastic recycler has contacted him. You can probably guess who that is!
Message in a bottle – This bottle containing mixed granulated materials was used to illustrate what floats and what sinks … which is a VERY IMPORTANT aspect for recyclers. Annabé Pretorius of SAPRO explained: PET and PVC fragments sink because their densities are more than 1 g/cc (which is the density for water); and polyolefins float as they have densities of less than 1 g/cc (i.e. 0,920 g/cc). Polystyrene is a bit more complex: its density is 1,01 g/ cc, which means it will float in brackish (salty) water but will sink in fresh water!
Rowan le Roux of Polyoak, resplendent in a ‘leather’ jacket made from rPET (yep!), and Kiril Dimitrov of Woolworths were among the presenters
Rubber Reclaim Explained, by ENV&E
BY KATHY GARDE
Too much excellent quality production scrap ending up in landfills ENV&E is a company from Pietermaritzburg, formed by husband-and-wife team Rosalie and Gareth Akerman. Gareth is a mechanical engineer with DPRI certification and Rosalie is an architect, but, very simply, they are two South Africans who have undertaken to provide
an economic and environmental solution to some of the issues that plague our rubber industry. ENV&E produce rubber crumb which is 100% metal free and achieve this by selecting only the highest quality industrial rubber production scrap and flashing, which is clean and of known composition. Imported crumb is generally of poor quality, often with an ash content as high as 40% and very undesirable acetone values,
pointing to rubber that has been recycled too many times or has a poor quality source to begin with. ENV&E, however, produce high quality rubber crumb with a very low ash content, consistent particle size and physical properties, which, when incorporated into rubber formulations, results in a significant cost saving without a reduction in performance. ENV&E is already REACH approved in Europe and is in the process of obtaining
Coen Burger (IOM³ EC Chairman), Gareth and Rosalie Akerman (ENV&E), and Ron Dunwoodie (Carst & Walker)
PCA bids farewell to Mike Bullock ing. During its short ‘life’, the PITB develTHE Plastics Convertors Association bade oped a career path for setters in the industry farewell to Mike Bullock, the man who leading up to the created qualification of helped build up the organisation over the ‘plastician’. past decade, at its annual general meeting After the dissolution of the PITB in 1999, in Midrand in August. Mike was appointed as the first direcMike joined what was the Plastics Fedtor of the PCA. Membership at that point eration of SA in 2000 and then the PCA in was about 35 companies and the figure 2001. Prior to that he enjoyed an extended increased to around 300, essentially through career in the industry, first in the converting keeping members informed about what was sector and later in training. He started out happening. To this end, he compiled 549 with Metal Box in Zimbabwe in 1972 and issues of the PCA’s later was MD of the newsletter ‘Informagroup’s Central Africa Mike put special effort tion’ over a period of plastic division. In 1982 into visiting converting 11 years from July he moved to the Metal companies around 2000 which is equivaBox company Aries lent to about 46 per Plastics in Durban, the country. year. If that wasn’t after which he joined the erstwhile Sentrachem group, also in SA. enough, he also produced over 50 ‘Stop Press’ issues. The effect of this was that But he really found his feet when he was PCA member companies were informed appointed manager of the Plastics Industry of goings-on – and that sustained level of Training Board in 1993. It was virtually communication proved effective in building an emergency appointment as the first up the organisation and keeping member incumbent vacated the post very suddenly. companies informed about activities, as well Although he had little experience in training, as matters such as tariffs and duties and Mike was exceptionally good at coordinat-
Last laugh! – Mike Bullock received a gift from Johan Pieterse at the AGM; looking on at left is PCA chairman Loutjie de Jongh. Mike’s main method of communicating was always comedy and, not surprisingly, he had quite a few quips at the farewell function
other state legislation. But Mike also put special effort into visiting converting companies around the country and finding out what their needs were, which was probably also a factor in the increased PCA activities. He has been semi-retired since 2008, living in Tzaneen in Limpopo, but commuting to Midrand quite frequently and continuing with the ‘Information’ series. Now, however, he’s opted to take fishing a lot more seriously! Well done Mike.
AkzoNobel’s product portfolio for rubber industry BY DES ROYAPPEN THE Institute of Materials, Minerals and Mining (IOM³) held a meeting on 27 June at the Victoria Country Club in Pietermaritzburg. The speaker was Hennie Strydom, regional sales manager for AkzoNobel XTP. He is a local boy but now based in Dubai. Hennie’s presentation was titled ‘AkzoNobel’s Product Portfolio for the Rubber Industry’. AkzoNobel is one of the largest global paints and coatings suppliers and is a leading producer of specialty chemicals. Hennie gave a broad overview of the chemicals it supplies to the rubber industry. AkzoNobel is very supportive of the IOM³ and has agreed in principle to make a sponsorship to the IOM³ conference in March 2013 and also present a paper. The sponsor for the evening was AkzoNobel.
ISO 9001 compliancy. They produce any mesh size from 4 to 60, but have the capability to produce to any specification required. They also offer ‘closed loop processing’, which means that their customers’ own scrap can be turned into crumb and supplied back to them exclusively, resulting in significant cost saving, ‘cradle-to-grave’ compliance, and peace of mind in knowing the origin and quality of the crumb. Next in their product line-up is rubber reclaim and, with machinery on the way already, they will soon be producing topquality butyl and tread reclaim.
Fourene Smith (Continental Tyre, IOM committee); Grant Rosettenstein (West African Group) and Kathy Garde (Carst & Walker, IOM committee)
Natural rubber: A global perspective DESPITE the cold, wet and stormy weather, a full-house crowd attended the presentation by Grant Rosettenstein of West African group in Port Elizabeth on the last day of July. Grant’s insightful presentation, titled ‘Natural Rubber: A Global Perspective,’ made this an extremely enjoyable evening, and the Old Brown Sherry helped us all to forget about the miserable weather outside. Grant presented a truly global view of the NR market, providing interesting and
relevant facts on rubber tree plantations around the world, focus areas, production volumes, pricing history and future expectations. He drew parallels with other markets and highlighted the primary factors which seem to affect the global demand for natural rubber and, in particular, the pricing of this rubber industry commodity. A truly interesting evening, thoroughly enjoyed by all. Thanks to West African and Orion for sponsoring the evening.
Institute of Materials: Southern Africa Region 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
Northern Spike Taylor p. 011 928 4172 c. 082 456 5734 spiket@multotec.co.za
www.iom3.co.za
www.iom3.org
OCTOBER / NOVEMBER 2012 39
FEATURE
TECHNICAL HINTS BY KARL SEIDEL, SEIDEL ELECTRONIC SYSTEMS
MACHINE CLAMP FORCE WHEN melted material gets injected into a mould under pressure, the mould halves and cores need to stay in position to avoid flashing. We need a certain clamping force to achieve this. This clamping force can be calculated by using the projected area of the product that is at a right angle to the direction of the injection, then multiplying it by a constant given in the following table.
Thermoplastic
Tons/cm2
HIPS HIPS (Thin wall) ABS HDPE PP Acrylic PC
0.155 - 0.31 0.388 - 0.543 0.388 - 0.62 0.233 - 0.388 0.233 - 0.388 0.31 - 0.62 0.465 - 0.775
For example, if we have a PS thinwall product with a projected area of 160 cm2 we would calculate 160 * 0.388 = 62.08 tons min, or 160*0.543=86.88 tons max. Now, let’s calculate what this will be in a 60 ton or an 87 ton machine. In order to make a decision we will use the ‘flow path length’ with a few clever tables. The ‘flow path length’ is the distance from the injection point to the point furthest away of the article. See the diagram below:
Let’s say the flow path is 150 mm and the product’s minimum wall thickness is 0.8 mm. The ‘flow path to wall thickness ratio’ will be 150/0.8 = 187, 5:1. By using Graph 1, we can see the cavity pressure is approximately 475 bar. The unit conversion tables shows us that 1bar = 1.02kg/cm2, therefore the clamping force = 475*1.02 * 160 = 77.52 tons. If using an 80 ton machine, add 15% to the clamping force. This is ideal for PS as it has a Thermoplastic
Viscosity Factor
PS PP PE ABS PMMA PC PVC
1 1 – 1.2 1 – 1.3 1.3 – 1.5 1.5 – 1.7 1.7 – 2 2
viscosity factor of 1. If you want to mould the product using ABS, you would encounter problems as the clamping force of 80 tons would not be sufficient. The viscosity factor of ABS is 1.5 (as seen in the table below). To calculate the clamping force you would need to multiply 77.52 by 1.5. This shows us that we would need a 116.28 ton machine, or in the case of PVC, a 77,52 * 2 = 155,04 ton machine. Confirm this with your mouldmaker as he can also do this using a CAD system. Unit Conversions 1N 1kN 1Nm 1 bar
0.102 kg 0.102 ton 0.102 kg-m 1.020 kg/cm2
DPI offers Canadian students insights into local engineering AS a leading manufacturer of water reticulation, drainage and pipe-fitting systems in South Africa, DPI Plastics provided a group of 25 post-graduate engineering students from the École Polytechnique de Montréal in Québec with a unique insight into the company’s manufacturing processes during a site tour which took place in Cape Town earlier this year. The international visit forms part of the Poly-Monde council world tour, which has involved the selection of a new global destination for engineering students annually for the past 23 years. Poly Monde board chairman Bernard Lamarre highlights the fact that South Africa was selected as the destination of choice for 2012, due to its economic power in the region. 40 OCTOBER / NOVEMBER 2012
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THE CHALLENGE OF FINDING
AND KEEPING GOOD EMPLOYEES Labour markets in Middle East relies heavily on foreign workers BY DR NIALL MARSHALL
FEATURE
Even in a world of increased automation, business owners and managers are faced with the challenge of finding and keeping good employees. In certain countries these challenges are further complicated by shortages of suitably skilled, qualified or experienced workers and by local employment laws and regulations. The labour markets in the Middle East all rely heavily on foreign workers. In Saudi Arabia almost 90% of people employed in the private sector are foreigners. The oil price boom of the early 1970s resulted in the dramatic growth of the petro-economies of the region. Shortages of certain skills required could only be addressed by recruiting foreign workers. At the same time it also allowed the menial work in the inhospitable climate to also be outsourced to foreign workers. Over the years various factors have continued to contribute to a reliance on foreign workers including an historical preference among local citizens to take up employment in the public sector (due to better salaries and conditions of service), a willingness (and the finances) of the rulers to create government jobs to employ their citizens and an education system that was not well suited to training students for the workplace. Private companies have also contributed to this situation by hiring foreign workers for a fraction of what they would need to pay local citizens to do the same job (specifically with respect to unskilled or semi-skilled workers). But with more than 60% of the Saudi population under 24 years of age Construction workers in the Middle East
42 OCTOBER / NOVEMBER 2012
and youth unemployment over 25% it is an unsustainable situation. Just to keep up with the demographics requires that an additional 400 000 jobs be created per year – beyond what even the oil-rich Saudi state can afford to absorb in the public sector. Private sector job creation for local nationals is a priority in all the oil-rich Middle Eastern countries, and has been for some time (although the spectre of Arab Spring uprisings has, perhaps, given it a renewed urgency). There are two approaches being taken in private sector job creation: a focus on attracting foreign companies to invest in manufacturing, including plastics converting, and ‘localization’ policies. Localization is a requirement that a certain percentage of any company’s workforce should be citizens – in Saudi Arabia it was 30% of any company employing more than 10 people. Clearly with only 10% of the private sector workforce being Saudi nationals, the policy was not working and in 2011 a Royal Order was issued to correct this. The new system, known as Nitaqat, has a layered approach to quotas. Companies are categorized by their business activity as well as their size and this determines the quota which needs to be met. For example, banks with more than 500 employees need to have more than 49% Saudi Arabian staff. In the manufacturing sector, including polymer converting, the target is over 15%, while the oil and gas sector has a target of 45%. Companies are rated on a ‘traffic light’ system: companies rated as green are seen as being compliant whereas companies rated as yellow or red are not compliant and are subject to certain sanctions, including not being allowed to hire new foreign employees or even renew the work permits of existing employees. In the first year of the
Nitaqat system it is reported that over 380 000 jobs were created for Saudi Arabians. But it has not been without controversy: many companies complain they are forced to hire unqualified or unsuitable employees to meet their quotas. In the plastics industry the pool of technically skilled Saudis is small and even in the private sector qualified Saudis prefer to work for the petrochemical companies or at large multinationals. Therefore the smaller converters have to rely on foreign operators, many from India or the Philippines, but they still need to comply with Nitaqat. This has led to jobs being created purely for compliance reasons which result in uncompetitive cost structures which limits their opportunities to grow. But it has also encouraged companies to become serious about training. Perhaps the Nitaqat system isn’t perfect, but the creation of a larger pool of technically skilled Saudis for the plastics industry will benefit the industry in the future and will reduce the reliance on short-term foreign workers, addressing at least two of the challenges of managers. And if Star Wars’ C3PO is to be believed about ‘androids: can’t live with them, can’t live without them’, maybe some managers will never really be happy! 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
Ex-pat labourers’ accommodation in the Middle East
FEATURE
Plastics power Olympic performance from start to finish WITH 26 different Olympic sports at the London 2012 Olympic Games, an estimated 10 million Olympic enthusiasts marvelled at what took place on the field of play. As athletes prepped for play and fans settled into their seats, international and domestic polymer companies could take pride in knowing they contributed to the durability, comfort and key playing surfaces of some of the London 2012 most highly trafficked venues.
SA at the 2012 Summer Olympics
The South African Olympic Committee sent 134 athletes to the Games in London, 70 men and 64 women, to compete in 17 sports. Field hockey and women’s football were the only team events in which the nation had its representation in these Olympic Games. After the nation’s dismal performance in the Beijing Olympics, South Africa regained the team’s success in London by winning three gold medals, two of them were from
swimming, and the other from rowing. Swimmers Cameron van der Burgh and Chad le Clos won the gold medals in the men’s 100 m breaststroke, and the surprising men’s 200 m butterfly. Furthermore, le Clos was able to beat the reigning Olympic champion Michael Phelps in the butterfly event. Four days later, he earned the silver medal in the men’s 100 m butterfly, an event in which Phelps won the gold medal. Van der Burgh, on the other hand, did not only
44 OCTOBER / NOVEMBER 2012
Wrapped up! Dow also provided the Wrap for the Olympic stadium at the London 2012 Olympic Games. The Wrap is made up of 306 individual panels – each approximately 25 metres high and 2.5 metres wide – stretching from the concourse ground to the upper tier of the outer stadium. The Wrap also features directional signage and shield exposed elements of the stadium from sight. The Wrap panels are made up of more than 50 solid colours that bear
the official ‘Colours of the Games’. The Wrap textile is a new and innovative solution - a lightweight polyester fabric with a polyolefin elastomer-based coating. This material allows the Wrap to meet the stringent sustainability requirements while ensuring the appropriate fire protection and printability needed for stadium and stage venues. The compound that coats the polyester fabric contains highly efficient flame
win the gold medal, but also broke both the Olympic record and the world record in the men’s 100 m breaststroke event. In athletics, two South African stars became in the highlight in the Games, Oscar Pistorius and Caster Semenya. Pistorius, a four-time Paralympic champion, made the Olympic history in the track and field by becoming the first double-leg amputee to participate in the Games. Semenya won the silver medal in the women’s 800 metres.
Bridgitte Hartley won SA’s first bronze medal at the 2012 Olympic Games, in the women’s kayak single K1 500m race. Hartley crossed the line at Eton Dorney on Thursday in one minute, 52.923 seconds (1:52.923). The gold medal went to Danuta Kozak of Hungary who finished in 1:51.456, followed a second later by Ukrainian Inna OsypenkoRadomska in 1:52.685
SA’s awesome foursome wins Gold!
SA at the 2012 Summer Olympics
Bridgitte Hartley wins bronze
retardants and high performance additive technologies (colorants, processing aids and stabilizers). Dow elastomer technology, made it possible for the first time to achieve a unique combination of durability, flexibility and fire performance, while meeting also all the other performance requirements like printability, mechanical properties and abrasion resistance. To date these combinations of requirements had only been achieved with established solutions from the market (polyvinylchloride, fluoropolymers and silicones) and not with a polyolefin based product.
OCTOBER / NOVEMBER 2012 45
The story of James Thompson, Matthew Brittian, John Smith and Sizwe Ndlovu is a a story where the underdog comes out on top. The awesome foursome won the first gold medal ever for South Africa in the men’s lightweight rowing event at the Olympics in London 2012. Even though it seemed the South African athletes were sleeping for the first 1500m of the 2000m race, out of nowhere, in the last 500 metres, the rowers pushed as hard as they could and overtook the favourites Denmark and Britain to win the gold medal.
FEATURE
Track a perfect balance of hardness & elasticity Polyurethane binders from Dow were used in the 5 000 metres of track underlayment at Olympic Stadium, helping protect the track from wear and provide a safe surface for athletes. Dow’s product (Voramer) binds together rubber particles that make up the track. The solution provides runners with the perfect balance of hardness and elasticity – ensuring a safe surface for both sprinters and long-distance runners. The track at London’s Olympic Stadium is designed for a lifetime of at least 10 years. Dow adhesives are comprised of raw materials, like automobile tyres, that make up the basic layers of the track.
Top Class Pitch The Olympic field hockey tournament at London’s Riverbank Arena played host to more than 75 matches and 380 competitors during the Games. To help set the stage for players to safely slide, tackle and fall without abrasions, a high-performance artificial turf system was specially developed for the Olympic Hockey Centre. Dowlex™ Polyethylene Resins from Dow were used for the artificial grass in all field hockey pitches, but not in the traditional green of artificial turf. The hockey pitches at the Olympic Park’s Riverbank Arena are vibrant blue, with a pink border. The ‘London Blue’ turf allows players, officials, spectators and the media to keep their eyes on the ball more easily because the blue
Green Speed Nike’s new GS (Green Speed) soccer boot was worn by many Olympians and weighed in at a mere 160g. The company says more than 70% of the material content is recycled, again including polyester from recycled water bottles and other packaging.
46 OCTOBER / NOVEMBER 2012
colour provides a high level of contrast against the yellow ball and white lines. Field hockey players are constantly driving their studded boots into artificial turf, causing stress and wearing down the surface. The most trusted industrial test for measuring artificial turf durability and resilience is the Lisport test, in which heavy rolls equipped with numerous studs are rolled back and forth over turf samples to offer a visual indication of how they might age over time as a result of typical usage. Dow commissioned a Lisport test at Ghent University in Belgium. After 20,000 cycles of the studded rollers, the artificial grass made with Dowlex LLDPE resin did not have any visible trace of aging.
FEATURE
Recycled bottles for uniforms Nike used recycled plastic bottles for the track-and-field uniforms worn by the U.S. team. The uniforms use an average of 82% recycled polyester fabric and up to an average of 13 recycled plastic bottles per uniform, according to Nike. More than 1 000 hours of wind-tunnel testing indicates the resulting uniforms are up to 0.023 seconds faster than previous versions, in no small part due to the fact that the Nike AreoSwift technology incorporates patterns and surface architectures on key areas, such as the forearms and legs, an innovation inspired by the dimpled surface of a golf ball that reduces drag.
Popular PVC Polyvinyl chloride (PVC) has proved a popular choice in the construction of facilities for the London 2012 Olympic Games, with more than 142 000m2 of PVC fabric used at various sites. PVC used at the Games includes at least 30% recycled content, was manufactured in accordance with the ECVM Industry Charter, met standards for effluent discharges and vent gases, and did not contain lead, mercury or cadmium stabilisers. The credibility of the sustainable VinylPlus initiative, which builds on the success of the Vinyl 2010 ten-year voluntary commitment to enhance the
sustainable production and use of PVC, has undoubtedly been strengthened by the policies put forward by London 2012. After the London event, all temporary structures were dismantled and recycled. A system of crushing, selective dissolving, fibre separation, PVC precipitation and solvent regeneration ensures that recycled PVC is of a high quality and can be reused with minimum impact on the environment. It is planned that some of the recycled PVC from London 2012 will be used in football stadiums currently under construction in Brazil for the 2014 FIFA World Cup… continuing a sustainable product chain to the next great world sporting event!
Velodrome (Hopkins Architects): 2 600 m² of PVC in highperformance surface
Royal Artillery Barracks shooting venue used 22 000 m² of PVC membrane
Aquatics Centre (Zaha Hadid) – 15 000 PVC temporary chairs and 8,000 m² PVC external wrap 48 OCTOBER / NOVEMBER 2012
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:
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• ACM • CR • EPDM • Epichlorohydrin • FKM • HNBR • HTV Silicone • IR • NBR • NR • PVC/NBR Blends • SBR & BR
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• ABS • Acetal • Additives • Composites • CPE • CSM • EVA • HIPS & GPPS • Nylon • PBT • PC • PVC • TPE & TPV • TPU
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• 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
ANCHOR CHEMICALS
• Anti-tack • Bonding Systems • Coated Powders • Factice • Masterbatching • Process Aids • Toll Manufacturing
customized solutions innovative technology
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
world class quality products
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leading international manufacturers
FEATURE
InsideOut moulding makes for light bikes American Kristin Armstrong won gold in the women’s time trial, riding a Felt DA bike which uses an ‘InsideOut’ moulding process. This process is a revolutionary internally optimized moulding process that completely eliminates excess material, and therefore weight, inside the frame tubes and junctions. Placing polyurethane inserts inside the frame during the moulding process - especially at the bottom bracket and head tube area - and then applying a precise amount of pressure and heat results in perfectly formed
tubes, inside and out. The frame weighed in at 1300g, including the seat post and headset. The Ultra Hybrid Carbon (UHC) material features a hybrid blend of high modulus raw carbon fibre. The stiffest fibres are used in certain areas of the frame, more durable fibres in others. Nano refers to a proprietary resin matrix that increases frame strength at the molecular level. Beyond apparel, polymers were used extensively to create the hi-tech, lightweight racing helmets cyclists wear. The EPS cushioning is generally shot in-mould to bond with the polycarbonate outer shell. The reinforcing inner cage may be a thermoformed composite structure. The plastics used also provide the design flexibility that allow for the airflow openings and channels that pull fresh air in and circulate hot air out the back. The bicycles themselves are real weight-savers as steel and aluminium have been replaced at the elite level almost universally by carbon fibre-reinforced plastic (CFRP) frames that combine extremely light weight with rigidity. Professional-level racing bike frames can weigh as little as 695g. CFRPs are again employed in the wheel rims. The net result is that the same available power is transferred more efficiently to motion, meaning a better energy-to-performance ratio. The composites’ design flexibility has also led to a move away from traditional tube shapes in frames toward more aerodynamic shapes with lower crosssections.
Winning solutions for water sports The American women’s eight rowing team, which secured its second-consecutive gold medal, rowed their way to a dominating victory in a CFRP shell, which, beyond being lighter, is also designed to be steadier in the water, again translating into more efficient transfer of power. DSM has similarly collaborated with the Dutch Olympics rowers.
Boats weren’t the only plastics featuring in water sports. The London Olympics white-water kayaking course was constructed using Lyons, CO-based S2O Design’s proprietary RapidBloc plastic blocks instead of concrete and permanently embedded obstacles. The blocks can channel water to precise specifications, and, because of the lightweight plastic-block construction, the course can easily be reconfigured for more recreational use. Glewood Springs, CO-based Whitewater Parks International (WPI) developed the planning-approved Compliant Design and course-related performance specifications for the newly launched Lee Valley White Water Centre in Waltham Cross, Hertfordshire, UK. 50 OCTOBER / NOVEMBER 2012
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OBITUARIES
George Douglas de Jager life into Xactics fledging ‘bag in the box’ DOUGLAS was operation which had begun exporting born in Oudtshoorn the product to the wine industry in Chile. on 4 October Douglas ran this operation until Xactics 1950 and after was sold to Kohler Packaging in 1984, at completing junior which point he took over running Xactics schooling in the as a division of Kohler. town moved on to From the beginning Douglas did not Kingswood College treat his involvement in plastics merely in Grahamstown. On as a ‘job’. He consumed vast amounts completion he was offered a scholarship of knowledge from text books on the by Anglo American Corporation to study properties of the resins and chemicals geology at Rhodes University. It took less used in the industry, as well as on the than two years for Douglas to realize that machinery used to process them. He a career in mining was not for him. His tapped into the knowledge of those father owned an automotive engineering with many years’ business in experience in the Oudtshoorn, As an individual, Douglas industry in long interestingly called possessed a very special question and Lenco, which intellect which allowed him answer sessions. Douglas joined to focus instantly on which Then he set about in 1970. issues were important. putting it into He felt practice. immediately at In 1985 he left the corporate home in the industrial environment and bureaucracy that was Kohler and a few years later, when his father was purchased 51% of Elvinco Plastics contemplating retirement, Douglas made situated in Atlantis, from the Pelkor him an offer for the business which he Group, taking with him two very continued to run until selling it in 1980 experienced colleagues, Arno Prins and and moving with his wife and two young Julian Sarembock. Within two years, sons to Cape Town. having made the business profitable Douglas enrolled at the University by improving factory efficiencies and of Cape Town’s Graduate School of focusing on the right customers and Business for the Master of Business products, Elvinco, along with Atlantis Administration course in 1981. In 1982 Non-Woven Textiles, was ready for listing he joined the Xactics Group, a pioneer on the Development Capital Sector of in the plastic packaging industry and the JSE. This heralded the rebirth of his passion for plastics was ignited. He Lenco, a name Douglas had retained remained involved in the industry for the when selling the business. remainder of his life. Lenco grew rapidly into an industrial One of his early tasks was to breathe
JUST BRIEFLY Engen achieves excellent outcomes in ISO 14001 audits ENGEN, the country’s leading petroleum products marketer, hailed environmental compliance efforts at a number of its key sites during the last two months, as ISO 14001 audit reports returned excellent performance for its refinery, SAFOR and Wentworth depot in Durban. LOBP (the Engen Lubes plant in Island View) is also ISO 14001 accredited and will be audited later this year as part of the annual auditing process required for 52 OCTOBER / NOVEMBER 2012
the certification. The company further expects the Richards Bay Joint Bunkering Services accreditation certificate soon. ISO 14001 exists to help organisations minimise the negative effects of their operations on the environment, enabling them to comply with applicable laws, regulations and other environmentally oriented requirements, and to continually improve on these.
Mpact delivers solid interim results MPACT, one of Southern Africa’s leading manufacturers of paper and plastics packaging, has reported a solid performance with half year revenue up 11.7% to R3.2 billion. Underlying operating profit for the six months ending 30 June 2012 was R222 million, 8.4% higher
BY STA AN ST TUB BBS
conglomerate, moving to the JSE main board before the end of 1987, driven by Douglas’ force of personality and special brand of business acumen. In 1991, Douglas had the pleasure of acquiring the Kohler Rigid Plastics division which he had managed in 1984/85 for Lenco and within a year had restored it to profit. It remained an integral part of the Lenco Group until 1998 when it was sold back to Kohler (by then renamed Malbak), upon the unbundling of Lenco. Douglas became CEO of the Malbak Group until masterminding its merger in 2001 with the larger Nampak Group. The next act defies belief - unless one knew Douglas! He acquired the very same Rigid Plastics Packaging division out of the merger along with styrofoam packaging manufacturer Versapak and housed them in – you guessed it – Lenco! He also acquired Malbak’s Sharp Interpack operations in the UK, also rigid plastics packaging manufacturers. Once again he applied his business acumen and knowledge of the industry to returning the businesses to profit. The South African businesses were sold at the end of 2003, but Douglas retained the Sharp business until 2011. As an individual, Douglas possessed a very special intellect which allowed him to focus instantly on which issues were important. He also had immense charisma and presence despite only being 5ft 5in tall. His humour and zest for life made him a perfect dinner guest and travel companion. He was a real largerthan-life character and will be sorely missed.
than the comparable prior period. These figures exclude the paper merchant business Paperlink, which was sold at the end of March 2011. In the plastics business, revenue of R823 million was 15.2% higher than the comparable period and underlying operating profit of R37 million was up by 64.9%. “Our plastics business performed well over the period albeit off a low base,” said Bruce Strong, CEO of Mpact. “The growth in revenue was driven by higher average selling prices on the back of raw material costs and volume growth attributable mainly to improved sales of bulk bins to the agricultural market and new business in the PET preforms, bottles and jars. We have also made good progress in optimising our operations.
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OBITUARIES
Hennie Swanepoel HENNIE Swanepoel was born on 2 September 1957 in Durban. He received his Springbok colours for basketball in 1975 and played U21 rugby for Natal – his love for rugby was confirmed by his attendance at any and every game that the Springboks, or his beloved Sharks, played in. He received an award for barefoot water skiing and was an avid snow boarder and skier. After matric he applied and was selected to do his pilot training with the South African Air Force. On completion of his pilot course he left the air force and in 1978 started working for Xactics as a technical trainee where he was later promoted to production manager. In 1984 Kohler Plastics purchased Xactics and Hennie was asked to stay on with Kohler
NEW APPOINTMENTS
New at Plastics│SA JENNY Macdonald recently joined Plastics|SA as personal assistant to executive director Anton Hanekom. Before joining Plastics|SA, Jenny worked for major auctioneering companies in Johannesburg. “This is my first foray into the plastics industry and I’m very excited about learning more about this dynamic and growing industry”, Jenny says.
54 OCTOBER / NOVEMBER 2012
BY PE ETER LOW WRIE
Plastics. He worked his way up to production director until 1987, when he received an offer from MCG Industries. Hennie was responsible for building and managing a new factory in Isithebe, Northern Natal, for MCG’s crate manufacturing, rigid profile extrusion and laminate tube division. In 1990 he received an offer to join Megapak (then part of the Mega Plastics division of Sentrachem) as project manager to set up a factory and infrastructure to produce 25 million crates over a 42 month period for South African Breweries, a world class challenge which he successfully managed. In 1994 he was appointed General Manager. In 1995 Nampak acquired Megapak and Hennie was promoted to national operations director, Gauteng regional director and was also a board member of Megapak Zimbabwe. In 1997, in partnership, he formed a new
Joining Hestico IVAN Forrest joined Hestico as Accountant on 1 July. He has an Honours Degree, B Com Accountancy and six years’ business experience. SHANITHA Wade recently joined Hestico in the human resources department, bringing with her 15 years’ experience.
company called Chespak (Pty) Ltd which specialised in plastic injection moulding and blow moulding. He grew the business to four manufacturing plants in South Africa and Zambia, producing crates and drums with an annual volume of 4 million crates and 1 million drums. In 2006 Hennie sold his shareholding and joined MCG Industries as Divisional Managing Director of their plastic injection moulding division, specialising in plastic crates, pallets and chairs. He remained with MCG Industries, where he also served on the Board of Directors, until his death. Hennie’s greatest achievement was his family. He was a wonderful husband to LouAnn and a loving and immensely proud dad of his children, Diane, Duane, Bradley, Guy, Matthew and Hannah. He will be greatly missed by his many friends and colleagues in the plastics industry.
Polymer science as postgrad degree course THE 4th Polymer Science Winter Week held at Stellenbosch University in July was attended by 26 final-year students from the University of Cape Town, Walter Sisulu University, the Nelson Mandela Metropolitan University, the University of Pretoria and the University of Fort Hare. Stellenbosch University is the only university in the country to offer polymer science as a postgraduate degree course. Undergraduate modules in polymer science also form part of the academic offer by the Department of Chemistry and Polymer Science. “We use this week to expose students from right across the country to polymer science as a study and research option here at the University and to expand their knowledge of the application of chemistry,” says organiser Prof Albert van Reenen of the Department of Chemistry and Polymer Science about the Winter Week.
Barry Stewart BARRY Stewart of ITB Plastics of Isithebe, who passed away in July, was one of the best known individuals in the industry in KZN and was well respected in the film extrusion, printing and bagmaking business nationally. He had been involved in the industry for close to 50 years, although he had taken a ‘back seat’ over the last few years. Barry was born in Durban in 1932. He was indentured in 1949 as an apprentice in the printing trade as a hot metal compositor. Barry moved into sales with Press Supplies in the paper supply industry before joining A&J, a sports goods agency and moved to Rhodesia to open an office. In 1964 he returned to Durban and took up an appointment as sales rep with
The Durban Bag Company which was producing bags in hessian and cotton, with a fledgling plastics division. He was promoted rapidly through the ranks, made sales director in 1967 and Managing Director in 1972. At the time film extrusion, printing on to plastic and bag-making were still in their infancy in South Africa, so all those involved were on a challenging learning curve. Barry was able to take the process a step further and, just over 20 years later, decided to go on his own and founded ITB in 1985, based at Isithebe, about an hour’s drive north of Durban. The government at the time offered incentives for start-up businesses in semi-rural areas such as the North Coast, but although that provided an advantage, finding and training production staff was not a simple matter. Barry was able to manage this and the fact that ITB remains one of KZN’s top film/bag manufacturers is testament to this. Barry’s production ‘policy’ was to invest
in high standard equipment and from the start ITB purchased machinery from top European marques. He was also a man who stood up for what he believed in, which was something he was respected for. He was a recipient of the Hermann Stiegler Award, presented by the former Plastics Federation of SA for outstanding achievements by individuals in the industry in SA. He also served as chairman of the Plastics Convertors Association in KZN on a number of occasions. Barry’s philosophy of ensuring customer satisfaction through excellence in quality was the driving force in the establishment and growth of the company. Today ITB is amongst the leaders in quality packaging in South Africa. In his years of retirement Barry enjoyed visiting the factory to remember the ‘old times’ with many of the long serving staff and was fiercely proud of the company. Barry married Moira in 1958 and leaves two children, Tim and Mich, both of whom work at ITB Manufacturing.
Tuffy Brands clean up schools with City CAPE based Tuffy Brands, manufacturers of 100% recycled refuse bags, signed a partnership agreement with the City of Cape Town in September to supply 60,000 free refuse bags for school clean-up events to 30 schools participating in the WasteWise Eco-Schools project across the Cape metropole area. Rory Murray, marketing director at Tuffy Brands, signed the agreement with Councillor Shehaam Sims, Mayco Member for Utility Services for the City of Cape Town, at the Oval North School in Mitchells Plain where Tuffy will provide 5,000 refuse bags a month for clean-ups around the Western Cape. The WasteWise programme is one of the city’s integrated waste minimisation and awareness programmes aimed at encouraging action among the general public and businesses of Cape Town to minimise waste, reduce littering, stop illegal dumping and increase recycling.
www.tuffy.co.za
OCTOBER / NOVEMBER 2012 55
TECHNICAL
Faster production is
in the bag! New silicon vacuum bagging technique is streamlined, controlled Trading old for new A SIMPLE technique that makes use of a Advanced Materials Technology (AMT) reusable silicon bag is changing the way is the local agent for Smooth-On and that composite parts are manufactured introduced the new technique to the in applications as diverse as aerospace, country’s leading manufacturers during a marine and even architectural industries. series of demonstrations at its offices in Composites have found favour in Johannesburg, Durban and Cape Town many niches where the non-corrosive recently. During the demonstration silicon and light weight-to-strength capabilities bags were made and quality composite are unmatched by metals or plastics. mouldings produced in just a few hours. Anything from modern-day supercars to “Vacuum bagging has been practised passenger aircraft are manufactured from for many decades and is the preferred these manmade wonder materials. But, technique for production of moulded items. the moulding process is a complex and It makes use labour intensive of plastic sheet job that requires The reusable silicon bagging material that is cut many hands and a technique is far less complex to shape and placed lot of consumable over the material to products to ensure and much less likely to be formed onto the the materials are fail than conventional mould. An airtight correctly set in vacuum bagging seal is then created place. using special tapes The new silicon and sealants and when completed is ready vacuum bagging technique, however, to be used. A vacuum is applied which changes this. It was developed by UK draws the plastic against the materials and based composites expert, Alan Harper, onto the mould,” explained Paul Carnell, in collaboration with developers from AMT product specialist. leading supplier of silicon, composite The required resins are then introduced and moulding materials, Smooth-On. It through a port (or ports) located at a point effectively transforms the process from a along the length of the mould. This is known comparatively messy, complex process to as infusion, a process which allows the a streamlined controlled process. Step 1 – Making the reusable silicon bag begins with putting vacuum ports and other fittings in place on the master mould before the silicon is applied STEP 1
56 OCTOBER / NOVEMBER 2012
Step 2 – Smooth-On’s Brad Frikkers demonstrates how silicon is easily sprayed onto the master mould to hold specialised fabrics used as reinforcing, as well as required fittings, in place STEP 2
liquid resins to seep through the layers of fibre and set to the mould. Once the material has hardened it is removed from the mould and the plastic sheet along with all the tapes and sealants are disposed of. Residues from tapes and sealants then need to be removed before new sheets are cut and carefully taped into place for the next moulding. “This is a global technique that has been used for decades when moulding composites. Despite this it can be tricky, particularly if a micro hole appears in the sheeting or if resin flows are impeded for any reason. Shifts in material as a result can cause the failure of the entire process and materials involved will be scrapped resulting in a costly failed exercise,” added Paul. Drop in place The reusable silicon bagging technique by comparison is far less complex and much less likely to fail than conventional vacuum bagging. The bag itself is made by applying silicon directly onto the mould that will be used in production. This is either done by hand with a brush, or using Smooth-On’s EZ-Spray silicon and spray applicator. Premade resin inlets, as well as vacuum ports and lifting points are put in place before applying the silicon. Step 3 – Final checks are done to ensure infusion ports and fittings are correctly in place before layers of silicon are applied STEP 3
Manufacturing with the reusable bag – After composite materials have been put in place on the master mould, the reusable bag is simply put in place and vacuum applied before resins are infused
Special reinforcing material can be introduced at any point to give the bag special properties like non-stretch areas around sharp edges or for lifting purposes or to create more rigid sealing and vacuum channels to fit onto the flange of a mould. It is really up to the user what properties they require. Once the mould is completely covered and a thick enough wall of silicon has been created it is time to let it cure. Once cured the bag is immediately ready to use – over and over again. In order to begin the moulding process the same set up technique is used. Just as before it requires that the fibre be laid correctly, but this time the bag is simply put in place over the mould. Vacuum is applied and resins infused through the built-in ports. Once set the mould can be repopulated with fibre and materials and the process repeated
again and again with no mess and no consumables. Easy solution During the presentations, Smooth-On’s Brad Frikkers explained that the major advantage is the reduced setup effort. The conventional vacuum bagging technique requires the plastic film to be shaped, prepared and fixed in place each time it is to be used. The reusable bag, by comparison, is simply put in place and used. Depending on the resins the bag will have a lifespan of between 30 and 500 cycles, saving the manufacturer the same amount in time and labour. “After about 18 cycles the cost of the materials alone reaches parity. Furthermore, labour time is reduced by about 90% and productivity ratios improve dramatically as a result. At the same time waste is avoided
Step 4 – With everything in place the silicon is simply sprayed on. When cured, it will form an elastic skin that incorporates the required vacuum seals, ports, lifting supports etc and is the basis of the reusable bag. Silicon may also be brushed on instead of being sprayed on STEP 4
An example of a finished moulding using the advanced reusable bag system from AMT Composites
and scrap as a result of slippages is also reduced. There is also no limit to the size of the bag - provided a technique can be found to place it and lift it,” said Brad. Other advantages include faster production times, better heat resistance of up to 260° C, no odour and smaller stock holdings of mould materials. It is expected that through the combination of cost and labour savings the vast majority of composite materials moulding operations will adopt the new technique in the near future. • ADVANCED MATERIALS TECHNOLOGY, PAUL CARNALL, TEL: (011) 392 4232, FAX: (011) 974 4198, EMAIL: PAULC@AMTCOMPOSITES.CO.ZA www.amtcomposites.co.za
Step 5 – After the silicon has cured it is simply lifted off the master mould and is ready to be used. No releasing agents are needed STEP 5
OCTOBER / NOVEMBER 2012 57
TRAINING
Materials research aims to
solve pressing local problems Nanotechnology and green chemistry principles to find cost effective solutions POST-graduate students and their study leaders at the University of Pretoria’s Institute of Applied Materials (IAM) are hard at work applying nanotechnology and green chemistry principles to find cost effective solutions to pressing South African problems. These include industrial challenges for environmentally friendly products for the export market and ways to relieve the debilitating effects of diseases such as malaria.
IAM is an interdisciplinary materials research group in which the Departments of Physics, Chemistry and Chemical Engineering participate. The Institute is associated with two SARChI Chairs conducting research into carbon- and fluorine-based materials respectively. It is currently home to four professors and in the region of 40 post-graduate students who are participating in cutting-edge research that will put
the University of Pretoria on the forefront of materials technology. According to Prof Walter Focke, director of IAM and coordinator of post-graduate training in polymers and chemical product design, the research programmes at IAM prepare students for creative careers in the downstream chemical industry. For IAM the ideal research outcomes are those that contribute towards solving major
Record breaking!
58 OCTOBER / NOVEMBER 2012
SA’s Composites Training Academy helps in world land speed record attempt THE Composites Training Academy of South Africa (CTA) has embarked on an exciting project working with Bloodhound South Africa to create awareness about composites and their use in the Bloodhound ‘rocket car’ that will attempt a world land speed record in the Northern Cape in 2013. The Bloodhound SSC Project is an attempt at the world land speed record with a car that is being designed to travel at 1 690 km/h. The Composites Training Academy has been asked to build a full scale ‘show car’ version of the Bloodhound. The show car will be used, as was the one built in the
The Composites Training Academy has been asked to build a full scale ‘show car’ version of the Bloodhound. The show car will be used, as was the one built in the UK (above), as a marketing, promotional and educational tool leading up to the record attempt next year
UK, as a marketing, promotional and educational tool leading up to the record attempt next year. “The number one aim of the project is to inspire the next generation of engineers and scientists by sharing all the project information with learners and their teachers with schools across South Africa,” says Oliver Dawson,
CEO of the Composites Training Academy. The car will use the very latest manufacturing technologies and the front end will use composites extensively for the driver’s monocoque cockpit and for the jet intake structure to the EJ200 engine. www.compositetraining.co.za
Designing with Plastics THE University of Pretoria’s recent ‘Designing with Plastics’ plastics short course held during August attracted 41 delegates and 20 students. This intensive two-day seminar reviewed aspects of the current state of the art in plastics engineering. It dealt with innovative aspects of material selection, plastics product design for manufac-
Jaco Scheepers of Sasol, Sanet Cilliers of Idwala and Grant Smith of Sasol Modderfontein were among the delegates who attended the University of Pretoria’s recent ‘Designing with Plastics’ plastics short course held during August
ture, plastics conversion techniques (especially injection moulding) and life-time prediction. The delegates were particularly impressed by the innovative approaches that are currently developed for onestep injection moulding of complex part assemblies that previously required a significant number of post processing and operations.
Prof Christian Bonten, Director of the Institute of Polymer Technology (IKT), Stuttgart University,Germany, who presented the short course and Prof Walter Focke, Institute of Applied Materials, Department of Chemical Engineering, University of Pretoria (UP) at the occasion of the Plastics Engineering.
Chris Oberem of Hestico with Prof Christian Bonten
societal problems, such as those posed by diseases such as malaria or the successful commercialisation of new technology that enhances the competitiveness of local industry. Thus IAM’s research efforts are aimed at solving real engineering problems, rather than just generating new scientific knowledge. Towards prophylactic malaria control According to the World Health Organisation (WHO), malaria caused an estimated 655 000 deaths, mostly among African children, in 2010. In southern Africa malaria is controlled by widespread indoor residual spraying of DDT. While this practice saves lives in the short term, DDT may have negative health effects over the long term. The Institute is a member of the UP Centre for Sustainable Malaria Control (malaria@ up.ac.za) where it helps to explore novel physical and chemical methods that may ultimately help to eradicate the malaria scourge. Research conducted at IAM includes safer ways to control malaria mosquitoes by using WHO-approved insecticides incorporated into coatings, polymer fibres and netting. This research programme has received funding from Sasol towards developing a long-life polypropylene mosquito net (LLIN) and from the Bill & Melinda Gates Foundation for an insecticidal paint-approach for indoor residual spray.
“We also had a Mozambique-South Africa research grant to explore the use of local clays as devices to control the release of residual insecticides. It is hoped that, through this research, we can replace DDT currently used in spraying with more benign alternatives,” says Prof Focke: “Our results indicate that this may indeed be possible. We are currently negotiating with the Industrial Development Corporation to conduct large-scale field trials and to set up local production of such a product based on our technology. Our future research efforts will focus on strategies to overcome the impending problem of mosquitoes developing resistance to the WHO-approved insecticides.” Adding value to southern African clay minerals Another IAM research programme seeks to upgrade both synthetic (layered double hydroxides) and natural layered clays minerals (vermiculite, bentonite and phlogopite) from South Africa and Mozambique. Nanotechnology is applied to develop systems for the controlled release of actives, such as insect repellents or insecticides as mentioned above; to modify and tailor clays for application as functional additives in polymers to enhance mechanical properties, improve heat stability of PVC and flame-retardancy of polyolefin polymers. Another activity aims to control mate-
rial oxidation behaviour, either to provide better stability for longer service life or to enhance mineralisation of plastic litter. IAM research has also produced volatile corrosion inhibitors for plastic packaging. These are currently used in packing used for steel and automotive parts exported from South Africa to ensure that they reach their destination free of rust. IAM research groups also apply nanotechnology towards developing ‘green’ pyrotechnic systems. The main focus is on time-delay mine detonators. Here the objective is to replace all heavy metal compounds with more environmentally friendly alternatives without sacrificing performance. www.aim.up.ac.za
OCTOBER / NOVEMBER 2012 59
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.
PRODUCTS
Dreaming of a
www.andycartwright.biz
green Christmas?
The festive new Korol Christmas Tree will be a talking point in any home this Christmas
Fully recycled designer tree FORGET Irving Berlin and his dreams of a white Christmas. Andy Cartwright Homeware’s new Korol Christmas Tree made from recycled plastic components will have environmentally conscious consumers humming a greener tune this December. Korol is a cutting edge modular design system that uses a recycled copolymer of polypropylene sourced form post industrial waste collected from factories in and around KZN. “It is very product-specific as our strong, lighter colours require cleaner material,” explains Cartwright. The tree is manufactured using star-shaped components or ‘building blocks’ that, when connected at their points, can form limitless
functional and decorative designs for the home. Starting with homeware like clocks, bowls and lamps, Andy Cartwright Homeware has now created the Korol Christmas Tree for people looking for a tree with difference that is also easy on the planet. The tree comes in a compact, kit form which is easy to assemble and portable further lowering its carbon footprint. Even the packaging is used as part of the finished product. Korol’s ability to transform into so many different products makes it sustainable and versatile. Using the building block approach, it is free to transform into homeware and design items that are modern, fun and inspiring.
DuPont showcases innovative solutions & collaboration New material, manufacturing solution DUPONT Performance Polymers (DPP) will be using this year’s Fakuma event to showcase a new material and manufacturing solution for a car suspension component with overall better productivity which uses renewably sourced polymers. The Jounce Bumper – an additional spring used in car shock absorbers to improve vehicle behaviour and comfort – is made from DuPont Hytrel TPC-ET and offers many benefits over existing PU-based alternatives. DuPont has developed a patented blow moulding process that ensures optimum energy absorption. Working closely with OEMs using non-linear Finite Element Analysis (FEA) software and the Expert System from DuPont, the design of the Hytrel Jounce Bumper can be optimised to meet static and dynamic requirements of the OEM. DuPont will also be highlighting many of its innovative sustainability solutions, including an extended portfolio of long-chain polyamides, which is undergoing accelerated market introduction, and includes modified 612 and renewably sourced 610 that are aimed at replacing PA12 on brake and fuel systems applications. Other sustainable products include DuPont Zytel 66 Halogen free which can
The thermoplastic Jounce Bumper is designed by DuPont Performance Polymers to replace incumbent foam polyurethane (PUR). Jounce Bumper is a part on the top of the suspension to prevent shock at the end of the metal spring compression and improve vehicle behaviour
withstand extremely high continuous temperatures thanks to a new heat stabilisation technology, and a broad range of DuPont Zytel HTN halogen-free nylons able to fulfil the most demanding applications such as Surface Mounted Devices (SMD) components and Hand Held Device (HHD) and the recently launched impact-modified, low-emission DuPont Delrin 300TE, which extends the scope of application of POM into multiple applications, including those in automotive interiors, where resistance to high impact loads is required.
www.fakuma.plastics.dupont.com
Recycled billboard & PVC vinyl GREEN is what the Intelligent Marketing team has on their minds most of the time, and it shows in their range of promotional products from recycled materials. All of their eco-friendly products are either recycled from post-consumer waste, or manufactured from sustainable resources. This Cape Town based company produces high quality bags and folders from waste billboard material or PVC vinyl. All of the company’s products are channelled through its Community Employment Programme (CEP). So far this project has helped create 10 permanent jobs.
www.iamgreen.co.za 60 OCTOBER / NOVEMBER 2012
Mpact’s new packaging solution for meat & poultry retail Healthier, more efficient way to pack raw meat, poultry MPACT’S new Ultrazorb foam tray draws more than double the amount of excess liquid away from packaged meat and poultry products. Most importantly, the new formulation of the tray, which is produced by Mpact’s Versapak operation in Paarl, improves the appearance of products as well as reduces the spillage associated with excess blood. The new Ultrazorb tray has been formulated with a special additive which enhances the absorption capability of the product. The technical research team discovered that the absorption capability of the traditional absorption pad (tray liner) currently in use in the food sector is approximately 17g over a 30 minute time period. Over the same time period, the Ul-
Unique sporty 500-ml bottle GREINER Packaging International packs new Xcel Milk that provides athletes with an innovative post-exercise recovery drink. Xcel Milk is a unique post-exercise recovery drink based on fresh milk. Produced in England, it promotes recovery after exercise, encouraging consumers to ‘train smarter’. A specialist in bottles and closures within the packaging producer Greiner Packaging, Division Kavo, has created a functional and sustainable packaging solution in cooperation with its customer. Designed by TGL Creative, the 500ml bottle is a classic, yet simple milk bottle shape. Embossed branding aids grip, and inclined lettering and multicolour printing add to a dynamic look. High-quality R-PET is used and the bottle is produced using injection stretch blow moulding technology.
www.greiner-gpi.com
trazorb trays absorb 40g – 140g depending on the specific item as indicated under the same conditions. www.mpsa.co.za Mpact’s new Ultrazorb tray has been formulated with a special additive which enhances the absorption capability of the product
World first for
skin care industry Resins combine renewable thermoplastics with oil-based polymer material INTERNATIONAL sustainable resins supplier Cardia Bioplastics and emerging organic skincare company Ecocare have partnered to produce a world first in the skin care industry: eco-friendly facial wipes enclosed in eco-friendly packaging. The biodegradable facial wipes are made from 100% natural certified organic cotton. The packaging incorporates Cardia’s renewable and recyclable Biohybrid™ resin which is derived from renewable resources. The resulting ‘green’ combination has a significantly lower carbon footprint than its competitors. “There is a growing trend for companies to look at ways to reduce the impact of their operations on the environment,” said Dr Frank Glatz, Managing Director of Cardia Bioplastics. “Product packaging is a good place to start. Our thermoplastic starch resins have a high renewable content – when they are incorporated into standard packaging or plastic products, the carbon footprint is reduced by up to 50%,” said Dr Glatz. Cardia’s Biohybrid resins combine renewable thermoplastics with oil-based polymer material to reduce dependence
The packaging for the ECOCARE™ biodegradable facial wipes incorporates Cardia Bioplastics’ renewable and recyclable Biohybrid™ resin, which is derived from renewable resources
on finite oil resources and to reduce carbon footprint. The renewable material is derived from non-genetically modified corn crop grown for industrial use. They are also compatible with current plastic recycling processes and are food safe compliant. www.ecocarenatural.com OCTOBER / NOVEMBER 2012 61
PRODUCTS
Improved humidity Bulk collapsible protection of medical devices bins Adsorbent technology is integrated directly into thermoplastics
CONCEPTAINER, specialists in the custom-design and manufacture of packaging for specific requirements, has launched a new recyclable, collapsible bin that is proving highly successful in diverse sectors, particularly in the automotive sector. “The new Thrift™ bulk collapsible bin, which only weighs 28kg when empty, is an efficient system for the storage and transportation of a wide range of products, including automotive components,” says Jonathan Johnstone, managing director of Conceptainer. “An important feature of this returnable packaging is each box is manufactured to exact specifications. The Thrift design concept enables empty bins to be stacked 12 high, which substantially reduces the costs of supply of products and recovery of containers. The bins are easily repairable and Conceptainer offers a repair and maintenance service for damaged bins which extends the service life of each Thrift bin. Special materials are used in the manufacture of these bins which include polypropylene, high density polyethylene and aluminium. Depending on the application, a plastic liner can also be used for enhanced protection.
SUD-Chemie Performance Packaging, a member of the Clariant Group, offers an innovative solution to meet growing demands from medical diagnostics and device customers for improved protection against excess humidity. Süd-Chemie’s antidusting Advanced Desiccant Polymer (ADP®) delivers exceptional adsorbent capabilities that are integrated directly into thermoplastics used in packaging or the device itself. The benefits of this technology include protection throughout the shelf life of the diagnostic or device, a wide choice of materials and processing methods, and the ability to customize adsorption kinetics to create an optimal end product. Moisture is a major pathway to degradation for diagnostics and devices. By protecting the microbiological stability of in vitro diagnostic (IVD) reagents and drug-device combination products against humidity, ADP helps avoid false readings and improve diagnostic accuracy for medical conditions. The polymer can be embedded in a thermoplastic and injection moulded as a single component or extruded as part of a multi-layer package system.
From this ...
62 OCTOBER / NOVEMBER 2012
www.clariant.com
New boxes dispose of mining headache
www.conceptainer.com
... to this, now thats amazing!
The multilayer pregnancy test cap is moulded by Süd-Chemie Performance Packaging and contains its Advanced Desiccant Polymer (ADP®), which protects the strip’s reagents from moisture degradation. (PHOTO: CLARIANT)
WHEN Minova RSA, an integrated supplier of resin support products and mining accessories, heard about a new environmentally friendly seafood box being launched in Cape Town, they knew they had found the answer to their most pressing logistical problem. The company had been struggling to transport rock bolts and resin capsules (anchor bolts used to stabilize rock excavations) in the wet conditions of South African mines. In other countries, such as Australia, the goods are transported into mines using reinforced or waxed cardboard boxes on
a pallet, but in local mines the boxes kept disintegrating due to moisture damage. Vice president of operations, Alfredo Piroddi, read an article announcing the launch of CoolSeal SA, a polypropylene box originally used in the cold chain for the delivery of chilled fish and meat, and recognized the potential of the boxes for transportation in mines. The CoolSeal range had been designed and extremely successful in Europe by UK group Tri-Pack Plastics, replacing the traditional expanded polystyrene box. The Ampaglas Plastics Group brought the product to South Africa in October 2011. The edges of the boxes are sealed through patented technology to create stronger, moisture-resistant packaging. After use, it is easily baled for recycling. The box is made from polypropylene, also known as twin-wall coruplast or correx. It provides the same strength as a reinforced corrugated cardboard box without being as heavy. The packaging can be easily retooled and made in virtually any colour, thickness or size. www.ampaglas.com
India’s ďŹ rst
injection moulded
plastic fenders Advanced thermoplastic technology from SABIC INDIAN automotive manufacturer Mahindra & Mahindra (M&M), with support from its Tier 1 supplier Plastic Omnium, has developed India’s ďŹ rst injection moulded plastic fenders, featured on the new critically acclaimed global XUV500 sports utility vehicle (SUV). Upgrading from steel to lightweight, online paintable Noryl GTX* resin manufactured by SABIC helped Mahindra & Mahindra to improve the SUV’s fuel economy, reduce emissions, greatly expand design freedom, and enhance resistance against minor impact. The use of Noryl GTX resin for the fenders helps make the global XUV500 one of the lightest SUVs in its class. SABIC provided application development assistance in addition to the Noryl GTX resin, which helped meet the OEM’s requirements of exceptional light weight,
online painting capability, improved gap and ush, and excellent low-speed impact resistance. The resin also gave Mahindra & Mahindra signiďŹ cant freedom to create aggressively ared fenders with accentuated curves and bold lines in line with the XUV500’s cheetah-like design. The biggest contributor to weight-out in a range of automotive applications is the conversion of metal to plastic. This led Mahindra & Mahindra to replace steel in the global XUV500 SUV’s fenders with Noryl GTX resin. This SABIC resin, which can be up to 50% lighter than steel, reduced the fender weight by 0.9 kg – a weight savings of 27%. Noryl GTX resin is a blend of polyamide (PA) and modiďŹ ed polyphenylene ether (MPPE) polymer technologies, which combines the dimensional stability, low water absorption, and outstanding heat
resistance of MPPE with the chemical resistance and ow of PA. The result is an extremely chemically resistant material with the excellent stiffness, impact strength and heat performance required for online painting. SABIC has continued to drive the development of better next-generation applications with new conductive Noryl GTX resins that provide a number of critically important beneďŹ ts. These include cutting coefďŹ cient of thermal expansion (CTE) by 20 to 40% vs. previous grades for increased dimensional stability and improved gap and ush management, giving automotive designers greater freedom to create larger top-quality, high-precision body panels than previously feasible. www.sabic-ip.com OCTOBER / NOVEMBER 2012 63
& & & & &
SOLUTION
MACHINERY (PTY) LTD
& & & & & & !$ " "# %
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
6
In Part I of this article in our August/September issue, Eric Solot discussed what ‘power factor’ is, the power factor correction of inductive tools, bulk power factor correction and static power correction.
Power factor correction and harmonics Harmonics are caused by many non-linear loads, the most common in the industrial market today are the variable speed controllers and switch mode power supplies. Harmonics cause a higher current to flow in the capacitors of a power factor correction installation because the impedance of the capacitors goes down as the frequency goes up. This increase in current flow through the capacitor will result in additional heating of the capacitor and reduce its life. Harmonic voltages can be reduced by the use of a harmonic compensator, which is essentially a large inverter that cancels out the harmonics and is an expensive option. Passive harmonic filters comprising resistors, inductors and capacitors can also be used to reduce harmonic voltages but this is also an expensive exercise. In order to reduce the damage caused to the capacitors by the harmonic currents, it is becoming common today to install detuning reactors in series with the power factor correction capacitors. These reactors are designed to make the correction circuit inductive to the higher frequency harmonics. Typically, a reactor would be designed to create a resonant circuit with the capacitors above the third harmonic. Adding the inductance in series with the capacitors will reduce their effective impedance at the supply frequency. Reducing the resonant or tuned frequency will reduce the effective impedance further. The object is to make the circuit look as inductive as possible at the 5th harmonic and higher, but as capacitive as possible at the fundamental frequency. 4
Reduced electricity costs Eskom provides working (kW) and reactive power (kvar) in the form of apparent power (kVA). While reactive power (kvar) doesn’t register on kW demand or kW hour meters, Eskom’s transmission and distribution system must be large enough to provide the total power. Eskom and the municipalities have various ways of passing along the expense of larger generators, transformers, cables, switches, etc., to the consumer. A reduction in apparent power results in a reduction in electricity costs. Reduced losses Losses caused by poor power factor are due to reactive current flowing in the system. These are watt-related charges and can be eliminated through power factor correction. Power loss (watts) in a distribution system is calculated by squaring the current and multiplying it by the circuit resistance (I2R). Increased system capacity Power factor correction capacitors increase system current-carrying capacity. Raising the power factor on a kW load reduces kVA. Therefore, by adding capacitors, additional kW load can be added to a system without altering the kVA.
75% PF Original Condition
VA 0k 8 4
100 142
=
70% PF
COSӨ2 =
100 105
=
95% PF
2 14
Ө1
A kV
e for Be
70% PF Before
er VA Aft 105 k 95% PF After Ө2
67 kvar Capacitor Added 100 kvar Before
Figure 7 – Apparent power before and after adding capacitors
64 OCTOBER / NOVEMBER 2012
317 kvar
360 kW
95% PF Condition
res mpe 70 A 5 A kV 474
148 kvar
Ө
450 kW Figure 8 – Power factor correction increases transformer output
Improved voltage conditions Low voltage, resulting from excessive current draw, causes motors to be sluggish and overheated. As power factor decreases, total line current increases, causing further voltage drop. By adding capacitors to an installation and improving the system voltage, motor efficiency, life and performance is improved. Industries benefitting most from power factor correction Low power factor results when inactive motors are operated at less than full load. This often occurs in cycle processes — such as those using circular saws, ball mills, conveyors, compressors, grinders, punch presses etc — where motors are sized for the heaviest load. Examples of situations where low power factor (from 30-50%) 7
33 kvar After
s re pe m A 8 57
Ө
Examples of power factor correction 5 Assume an active load of 100kW and an associated apparent power of 142kVA, resulting in a power factor of 0.70. By reducing the reactive power to 33kvar (by means of a 67 kvar power factor correction panel), the power factor improves to 0.95 and the apparent power decreases to 105kVA. The reduction of apparent power (37 kVA) not only results in financial benefits to the consumer (reduction in maximum demand and associated costs) but also a reduction in heat losses of the system.
COSӨ1 =
Benefits of power factor correction
occur include a surface grinder performing a light cut, an unloaded air compressor and a circular saw spinning without cutting. The following industries typically exhibit low power factors: INDUSTRY
UNCORRECTED POWER FACTOR
Saw Mills Plastic (Esp. Extruders)
45% – 60% 55% – 70%
Machine Tools, Stamping
60% – 70%
Plating, Textiles, Chemicals, Breweries Hospitals, Granaries, Foundaries
65% – 75% 70% – 80%
Factors influencing investment payback periods for power factor correction equipment Each electrical installation is unique and the required investment in power factor correction equipment as well as the associated payback period is influenced by the following factors: 8
Uncorrected power factor: the worse the uncorrected pf, the shorter the payback period of the investment in PFC equipment Requested target power factor: if the end-user insists on achieving a pf of 1 under peak load conditions (rather than 0.96-0.98), this will have a significant impact on the total investment required as well as the associated payback period Current and voltage harmonics present in the installation: if the harmonic levels are excessive, blocking reactors will have to be fitted in the PFC panel, which increases the investment costs, without there being a direct saving in maximum demand
REDUCED PROFITS
CAPACITY LIMITS
MAXIMUM DEMAND EFFICIENCY
INCREASED BILLS
Load changes: pulse loads (for example large spot welding machines required for the manufacturing steel meshing) require thyristor controlled PFC equipment, which has a negative impact on the total investment required Unbalanced loads: large single phase loads in a 3-phase installation such as large single phase welding machines, require single phase thyristor controlled PFC, which has cost implications Installation constraints: installation costs can represent a significant portion of the total investment in PFC equipment, especially for smaller installations of less than 150 kvar. Factors influencing the total installation costs are: Labour (man-hours and travel time) Cabling (size and length) Electrical consumables required for the installation of the PFC equipment Protection equipment such as (fused) isolators and circuit breakers Required IP rating of the PFC panel to prevent dust and water ingress Elevated ambient temperatures necessitating the fitment of air conditioning systems to the PFC equipment
Help your clients reduce their maximum electrical demand with our trusted products and services. • 24 month guarantee on our product range • The possibility to enter into service contracts • We provide training if necessary • Free audits of electrical installations • Flawless aftermarket service • A stock of spare parts and complete assemblies • Estimated ROI is between 6 – 18 months
Actual maximum demand rate being charged: ranges from R15/kVA to R138/kVA! This has obviously a significant impact on the payback period. PART III OF THIS ARTICLE, GIVING EXAMPLES OF SAVINGS AND INVESTMENT PAYBACK PERIODS FOR POWER FACTOR CORRECTION EQUIPMENT, 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 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 OCTOBER / NOVEMBER 2012 65
Tel: +2711 615 4640 • Fax: +27866 542390 Cell: +2772 546 5185 E-mail: eric@alphapowersolutions.co.za
www.alphapowersolutions.co.za
EQUIPMENT
New Z-Lock alignment locks outlast all others Longevity confirmed by extensive independent laboratory testing PROGRESSIVE Components have launched a new series of alignment locks that have been engineered to outperform all other styles. This is achieved through a combination of engagement geometry, materials and treatments, particulate capturing and lubrication distribution. Benefits of the new Z-Series alignment locks include: Longevity that far surpasses others, confirmed by extensive independent laboratory testing, as well as monitoring performance in harsh, ‘real world’ conditions. Exclusive features maintain clean consistent lubrication. Guide Lock, Side Lock, X-Series Side Locks and Top Lock styles available.
The Z-Series of alignment locks from Progressive Components have been engineered to outperform all other styles
C
A | Engagement ramp: A polished, radiused lead-in for smooth lifting upon engagement of the mould halves. B | Particle rings: Particle rings on the width of the male locks capture material and debris to avoid ‘picking up’ or galling of the alignment surfaces.
A B
F F
C | Longer engagement: Using the maximum allowable engagement area on all the locks advances previouslyestablished industry standards. D | Arced relief: Reduces the possibility of parts ‘hanging’ on the lock at the bottom of the mould.
E D
G G
E | Rounded edges: A larger radius for all protruding surfaces eliminates operator ‘reach in’ injury. F | Pry slot lead-in: Entry of pry slots expanded to ease removal. G | Premium materials: Males: H-13, 42-48Rc, salt bath nitrided. Females: D-2, 58-62RC, titanium nitride coating.
Independent tests conducted by Stork Technologies determined that the Progressive Components alignment locks exceed the 1 million cycle mark, whilst displaying no visible signs of wear of any type. “During the past year, over 20 different tests were performed with the purpose of cycling until failure occurred. At no time during our tests over the years have we seen cycle performance at the level of the new design, represented as lock number 1 in the chart.” • FOR MORE INFORMATION ON PROGRESSIVES’S Z-LOCKS AND OTHER PRODUCTS, PLEASE CONTACT MOULD & DIE SOLUTIONS ON 021 555 2701
66 OCTOBER / NOVEMBER 2012
www.m-d-s.co.za
www.procomps.com
Everything Hot Runners From single nozzles to fully assembled hot halves ... and everything in between Standard Series A series of products available in standard ranges, enabling the customer to configure and build a solution • Single Nozzles: off-the-shelf nozzles and tips for integration with moulds & components • Cool-One DIY: budget line of Do-It-Yourself projects for simple solutions with limited colour changes • Essentials: the essential range of manifolds and nozzles for up to 4-drop systems producing products for simple materials (PE, PP, PS) • Standard Systems: the solution for projects to be build using standard products from DME standard series
Custom Solutions Tailored, customer specific projects delivering high quality output • Advanced Hot Runner Custom Solutions: Turnkey solutions, starting from customer drawings, delivering full service • Cold Runner Custom Solutions: Turnkey solutions for silicone products
moulds & components runnerless solutions die sets Contact: Mould & Die Solutions surface finishing 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
Metal detectors an indispensable part of every plastics recycling system Sophisticated recycling technologies turn plastic waste into high-quality raw materials SINCE its foundation in the year 1983 Erema Engineering Recycling Maschinen und Anlagen GmbH in Ansfelden/Austria has specialised in the development and production of plastics recycling systems and technologies for the plastics-processing industry. The company’s international success is based not only on many patents and on particularly energy-saving and environmentally friendly systems, but also on its high quality demand and its customer orientation. The subject of plastics recycling is inseparably linked with matters of resource efficiency and sustainability. Waste plastics and reject materials from the plastics industry can be re-used in many production processes, provided that such waste materials are properly processed into highquality secondary raw materials. For the profitable returning of recycling materials into the production cycle Erema provides a wide range of products, e.g. plastics recycling systems for production waste and for heavily soiled post-consumer waste, and PET recycling systems for PET material that is of food quality again (bottleto-bottle). For decades Erema has successfully
S+S metal detectors (EREMA design) are integrated in the feed conveyor belts of EREMA systems for the inspection of the feed material. (PHOTO: EREMA)
cooperated with the Bavarian company S+S Separation and Sorting Technology GmbH. S+S supplies metal detectors and separators that are integrated in the feeding conveyor belts or pipelines of the EREMA systems. When plastic waste and reject parts are reprocessed, the feed material may contain metal particles that must be removed to protect downstream processing machines. S+S metal detectors identify magnetic and non-magnetic metal contaminations, even if they are enclosed in the product, and
thus prevent malfunctions in the plastics recycling process that are caused by metal particles. Metal detectors protect commination machines against damage, increase production reliability, optimise machine operating times, reduce malfunctions, and thus increase the profitability of the systems.
www.sesotec.com www.pet-recycling.com
New foam sheet die eliminates spider weld lines Better yield and eliminates need for edge trim DAVIS-Standard, LLC has introduced a new spiderless foam sheet die that improves processing of PS and PE materials for commodity and high-end foam sheet markets. The new die is capable of an extensive range of sheet thicknesses, widths and densities. It is also engineered to reduce downtime and maintenance while offering precision capabilities to improve quality and efficiency. The spiderless die eliminates spider weld lines and provides a uniform basis weight and thickness over the entire sheet width. This results in a better yield and eliminates the need for edge trim. The die also features a unique die lip gap opening and closing adjustment mechanism, which enables the operator to make modifications during production without interrupting the process. This control is further enhanced by an external die lip concentricity adjustment. 68 OCTOBER / NOVEMBER 2012
Other advantages include streamlined flow channels, up to three zones of temperature control, nickel plating on all wetted surfaces, and aluminum constructed internal and external air rings. Modular inner and outer die lip inserts make it possible for easier, inexpensive replacement of a damaged or alternative die lip design. A die lip fast gap feature allows for quick cleaning of melt contaminates. Die designs are capable of thicknesses from 1 to 12mm thick and for widths from 600 to 3048mm. www.davis-standard.com Davis-Standard’s new spiderless die eliminates spider weld lines and provides a uniform basis weight and thickness over the entire sheet width. This results in a better yield and eliminates the need for edge trim
The PTA utilises temperatures hotter than the ! "
! ! # $ %&' ( ) ' & This unit delivers the latest technology in microplasma welding. Relloy have been aligning themselves with the latest developments in the European market in order to provide European quality in the South African market.
RELLOY S.A.
(Pty) Ltd
27 Mopedi Road, Sebenza, Edenvale, Johannesburg, South Africa P O Box 8190, Edenglen, 1613, Johannesburg, South Africa Tel: +27 (011) 452-3724 Fax: +27 (011) 452-4722 KwaZulu Natal Cape
: Adele Eksteen : Enrico Anelli
083 395 2136 082 465 7639
email: dean@relloy.co.za Web: www.relloy.co.za
EQUIPMENT
TOTAL SOLUTIONS KOREAN company Yudo-Sans, a leader of hot runner systems globally and with more than 30 years’ experience in the plastics industry, develops, manufactures and services take-out robots, in-mould labelling systems, factory automation, mould temperature controllers, chillers, and material handling systems. In addition, the company provides a consulting programme aimed at maximizing customers’ profits. Yudo-Sans’ total solution technology is applied a broad spectrum of the plastics industry, including automotive, mobile and electronic goods and packaging. The company’s take-out robot has scooped more than 60% of the Korean market working with electronic giants like Samsung, LG, Hyundai and Kia. Yudo-
YUDO-Sans’ Giga-1012
Sans operates subsidiaries in 24 countries including North America, Europe, China and South Africa, servicing more than 4 000 customers. Yudo-Sans’ newest take-out robot, with its powerful motion control hardware, with payloads of 5, 8, 10, 20, 35 and 50kg cover injection moulding machines up to 4 000 tons. Benefits of Yudo-Sans’ high-end takeout robot series, Giga and Sonix include: Users can create their own sequences and monitor operation remotely via wireless route connection The robot ceases operation immediately it senses any risk of impact, protecting both the mould and the robot Huge energy savings with electricity consumption reduced by 18%.
YUDO-Sans Yucon-700
YUDO-Sans, Total Solution provider 70 OCTOBER / NOVEMBER 2012
The Sonix series includes 100 ton to 650 ton for 2 platen and 3 platen moulds. Its design is optimized for injection moulding application. Perfect motion control allows various extension options. The Giga series includes middle and large sized two platen moulds and its lightweight frame and powerful servo system guarantee high performance. Yudo-Sans also provide side entry robots for in-mould labelling, preform demoulding, as well as various packaging applications. • YUDO-SUNS PRODUCTS ARE SOLD AND SERVICED BY HESTICO IN SA www.hestico.co.za www.yudosuns.com
YUDO-Sans’ IML systems
Mould temperature controllers,chillers, granulators
Established 1962
LEFT: Parts in the 16-cavity mould at American Plastics Moulding Corp ABOVE: Sequence of five nylon 6.6 parts illustrating the problem that APM encountered with burning (far left) and how the problem was solved (far right) after installation of the Ion Series Controller
Boosting hot
Fast Heat’s Ion Series Controller
runner productivity
EQUIPMENT
Can reduce hot runner temps by 21˚C without gate freeze-off PRECISE control over hot runner temperatures was the key to ending a problem with burned parts that plagued a particular job being run by custom moulder American Plastic Moulding Corporation (APM), enabling the company to increase output of saleable product by 10 to 15%. The part discoloration caused by burning stopped almost immediately after connecting an Ion Series temperature controller from Fast Heat Inc. to a 16-cavity hot runner system that was producing 30% glass-filled nylon 6.6 parts for a Tier 1 supplier to the automotive industry, according to Alan Myers, APM plant manager. Within two hours after installing the controller, APM had fine-tuned the system to the point where temperatures were reduced by nearly 21˚C. “Before we installed the Fast Heat controller, we were unable to reduce the temperature without having gates freeze,” said Myers, “but within the first couple of
hours, it became a question of ‘How low can the temperature go?’ We soon established a new temperature range of 221 to 226 ˚C. The lower temperatures increased our output of good parts by 10 to 15% and eliminated the labour involved in sorting out parts that were burned.” Fast Heat’s Ion Series controller has also increased productivity in other ways, according to Myers. In startups it quickly tunes the system to the new set of moulding parameters. And in the event of a zone shutdown caused, for example, by a heater failure, the controller automatically slaves the affected cavity to another cavity, running two cavities from the thermocouple in the unaffected one. “In the past, when a zone shut down, we would end up producing from 15 cavities instead of 16, making that much less product during the typical three-day turnaround needed to replace the defective unit,” said Myers.
No compromise! 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
Family-owned and -operated since it was founded in 1971, APM is a full-service custom moulder that provides extensive engineering services and stages free quarterly seminars on design and engineering for customers and prospects. The company has 38 injection moulding machines, an assembly facility with lean manufacturing cells, an on-site mould shop, and a 5 575m² warehouse. www.apmc.com
Optimal contact between rollers and film yields improved transparency
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. 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 prelimi-
nary calibration, followed by three, five or seven rolls for final calibration. 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. www.battenfeld-cincinnati.com
The new Multi-Touch polishing stack from battenfeld-cincinnati yields excellent film quality attributes together with high output
72 OCTOBER / NOVEMBER 2012
Efficient development
BADAMID ® PA6, PA6.6, PA6.6/6
BADAMID
of plastic parts & injection moulding tools
®
PA12, PA6/6T, PPA, PA4.6, PA10T
BADATRON ® PPS
BADAFLEX ® TPE, TPE-E, TPU
BADAPRENE
®
TPV (EPDM/PP)
BADADUR
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PBT, BLENDS
Allows design to be analysed before injection mould is manufactured IN MANY industries the injection moulding process is the leading method used to manufacture plastic parts as cost-effectively as possible. The particular challenge here is knowing – before production starts – how the design of the parts will affect the manufacturability, and vice versa. Once again, construction-related simulation provides the solution. The injection moulding process itself is a complex mix of time, pressure, temperature and other material and toolspecific parameters. Previously this meant that designers of high-quality plastic components and tools have needed a large amount of experience to balance all these different variables. As well as the detailed design of the parts, feasibility in production also has to be taken into consideration from the very early phases of production development onwards. This avoids costly changes to the process and/or tool, as these changes could result in significant delays in the product reaching the market. The earlier this aspect of the design is optimized, the better. Simulation software packages offer one solution to the challenges of the injection moulding process: Users can carry out virtual tests under actual operating conditions and test their product designs at an early stage of development. Tests can be carried out throughout the entire design process depending on a wide range of parameters, and simulation can allow a design to be analysed before the injection mould is even manufactured. This avoids costly changes to the tool, optimizes the quality of the part that is then manufactured, and significantly reduces development times. Simulation-driven development of plastic parts SolidWorks Plastics provides users with powerful injection moulding simulation functionality, so they can identify
BADALON
®
PC
™
BADA
TAILOR MADE THERMOPLASTICS Innovatively compounded Engineering polymer solutions to achieve versatile properties • To include colour, UV and any other required additives • Tailor made solutions in consistently outstanding quality INCLUDING: Badamid™ range based on polyamide (PA6, PA6.6, copolyamide PA6.6/6 and partly aromatic PA6/PA6T) Badaflex TPE™ thermoplastic elastomers based on SEBS Badaprene TPV™ thermoplastic elastomers is rounded off by a wide range of partly crosslinked EPDM/PP blends
With SolidWorks Plastic users can analyse and optimize also thick and chunky parts that are solid in nature
www.bada.de SolidWorks Plastics helps to analyse and optimize a range of geometries including thin-walled plastic parts
Composite Plastics cc OCTOBER / NOVEMBER 2012 73
p/f. +27 11 314 1035 e. craig@compositeplastics.co.za | Craig: 083 680 9793 allan@compositeplastics.co.za | Allan: 082 886 6058
from page 73
potential construction-related problems and eliminate them in a targeted manner. The software is suitable both for designers of plastic components and manufacturers of injection moulding tools. SolidWorks Plastics is fully integrated into the SolidWorks software – so users work in a familiar environment. Changes to the 3D model are incorporated immediately and can be fed smoothly into the evaluation of manufacturability, avoiding the need for time-consuming and repetitive export/import processes. The powerful networking algorithm can quickly map even complex geometries – from very thin to more thick-walled and
mixed moulds. The software also has a comprehensive database that contains around 5 000 of the latest plastic materials and can be expanded and edited freely at any point. SolidWorks Plastics is available in two versions to meet different challenges. Designers of plastic parts can use SolidWorks Plastics Professional to evaluate the impact of changes relating to the wall strength, injection point, material and component design on the manufacturability of their parts. Developers of injection moulding tools can use SolidWorks Plastics Premium to gain in-depth insights into the behaviour of family moulds, including the
potential for optimizing injection points and/ or distribution systems. The simulation software provides numerous features that designers can use to make significant assumptions on the filling and holding pressure phase from very early in the development process. Shorter product development times Thanks to the precise prediction of potential manufacturing defects using the simulation functionality, troubleshooting phases which used to last for weeks are now obsolete. The design process is significantly more efficient as variants can already be inspected virtually for their suitability for use, allowing users to eliminate specific problems without having to carry out actual prototype tests. All in all, numerous factors support the use of simulation software such as SolidWorks Plastics in the manufacture of injection moulded parts or tools; in particular, reduced development periods, predicting and avoiding potential manufacturing defects at an early stage in the process, and increased product quality. www.mecad.co.za Unbalanced filling in family moulds (as seen here) can be predicted and avoided with SolidWorks Plastics
74 OCTOBER / NOVEMBER 2012
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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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
Converting end-of-life plastics into fuel represents a unique and profitable way to significantly decrease the volumes of these products that are disposed in landfills and incinerators
Rockwell Automation will design and build a new end-of-life plastic to fuel conversion plant in Bristol for SITA UK Ltd, in partnership with Cynar
$11 million contract for new end-of-life plastic to fuel conversion plant Rockwell Automation providing design, engineering life cycle maintenance, support local support. This win is significant for Rockwell Automation Global Solutions in the wasteto-energy market. It includes the design and build of process skids, automation architecture, software, power control and engineering and start-up services in one fully integrated solution, using the Rockwell Automation PlantPAx™ process automation system. Rockwell Automation’s Global Solutions team has worked with Cynar over the past two years to develop the engineering, modularisation and process improvements of Cynar’s waste end-of-life plastic to fuel conversion plant.
www.rockwell.com
EQUIPMENT
A LEADING technology company in the waste-to-energy market, Cynar plc, has awarded the leader in industrial automation, Rockwell Automation, an $11 million contract to design and build a new endof-life plastic to fuel conversion plant in Bristol in the United Kingdom, for SITA UK Ltd, a Cynar customer and partner in the development. Cynar has developed a technology that converts end-of-life plastics into fuel. The new technology represents a unique and profitable way to significantly decrease the amount of end-of-life plastics that are disposed in landfills and incinerators. Rockwell Automation strengthens Cynar’s technology by providing complete design, engineering life cycle maintenance, and
Cynar’s technology that converts end-of-life plastics into fuel is an important step in creating more sustainable energy sources
Techne launches new electric blow moulding machine Perfect match for medium production capacities TECHNE Graham Packaging of Italy has unveiled its new fully electric machine. The ADVT is a highly flexible full electric-meccatronic machine. Two versions, single or double shuttle make this new EBM unit the perfect match for the medium production capacities.
The Advance series is known on the market for its efficiency in terms of repeatability and consumption. With the ADVT, Techne Graham Packaging Company Italia has made a modern and efficient machine which focuses on low consumption, low maintenance and user friendliness. The result is a machine with an excellent design, which allows safe and easy access to any area for ordinary maintenance, head cleaning and quick tooling changing. The absence of any hydraulic systems assures a clean production environment,
a reduction of the overall noise and lower cooling needs of the machine. It also eliminates the problem of draining the used oil. Low consumption is assured thanks to several systems which have been tested and optimized during the last five years. The result is a 35% reduction in energy compared to hydraulic units, with a significant saving for the final user.
www.technespa.com
Techne Graham Packaging’s new fully electric machine OCTOBER / NOVEMBER 2012 75
EQUIPMENT At the Escha plant in Halver, Germany, eight injection moulding machines from Wittmann Battenfeld’s HM series have been installed
Innovative connection technology
76 OCTOBER / NOVEMBER 2012
Wittmann Battenfeld ideal for customized and special solutions IN THE course of expanding its production capacity at the end of last year, Escha, based in Halver/Germany, acquired 8 Wittmann Battenfeld injection moulding machines from the hydraulic HM series. Escha, a well-known manufacturer of plug-in connectors for sensor technology Escha Bauelemente GmbH will celebrate its 30th anniversary next year. The company was founded in 1983 exclusively as a stamping plant, and the production of injection-moulded parts was taken up in 1986. Today it operates two production facilities in Halver as well as its own separate logistics centre, with some 500 associates and about €42 million in sales in 2011. A new mould-making facility will be ready to move into shortly. The company’s key markets are in the automation industry and the mechanical and plant engineering sectors. Escha’s product portfolio is divided into three areas: tailor-made, specials and standard, with tailor-made contributing about 50% to total sales. With this high proportion of customized solutions as well as special solutions, Escha has achieved a unique selling proposition on the market and is
known as a trendsetter for plug-in connectors for sensor technology. Examples of customized solutions are detergent resistant or highly heat-resistant plug-in connectors, connectors with special data transmission functions or quick-connector technology, to name just a few. In manufacturing its innovative products, Escha relies on innovative injection moulding technology from Wittmann Battenfeld. In the course of expanding its production capacity at the Oststraße facility, Escha has invested in modern injection moulding machines from Wittmann Battenfeld’s HM series. These are hydraulic machines with clamping forces ranging from 65 to 180 t, consisting of 4 HM 65/60 machines, 3 HM 110/210 units and one HM 180/750. “The new injection moulding machines have enabled us to improve the coordination of our entire pool of machinery. We have categorized our equipment into three sizes and laid out all machine models belonging to each category in a similar way. This enables us to freely combine the moulds and machines from the same category with each other, which increases
Sensor plug-in connector from Escha
the flexibility and utilization rate of the equipment”, said Jürgen Sikora, head of materials management at Escha. Due to the high proportion of customized products and consequently small batch sizes, short changeover times were a vital consideration in the selection of the machines to be newly installed. Repeatability in injection moulding and correspondingly high product quality are equally important for Escha. The actual task was to realize the specifications laid down by Escha concerning shot weights and injection pressure by means of an appropriate machine concept. Fast delivery of the new equipment was also an important factor in its selection. Wittmann Battenfeld has been flexible in fulfilling Escha’s requirements and wishes. For instance, in addition to the option of eccentric injection, a number of other customized adaptations were implemented, such as mounting several sockets which require a high level of safety for the machines, and the addition of high-temperature tubes and special water filters.
www.escha.de www.mouldplas.co.za www.wittmann-group.com
Jochen Rüschenbaum, head of the Injection Moulding Department at Escha, Florian Schnell, PR/HR marketing Escha, Jürgen Sikora, head of materials managing at Escha with Frank Höher, salesperson from Wittmann Battenfeld
HM 65 with sprue picker and Tempro plus D temperature controller – everything from a single source
Valve plug-in connector – rear view, made by Escha
Loaders
Robots
Gravimetric Dosing Units
Injection Moulding
PET Wheel Dryer Beside-the-Press Granulators
Cooling Units
Water Regulators
Temperature Controllers
Neopor products can be used throughout the construction process, including interior and exterior insulation, flat roofs and pitched roofs, and for attic and basement ceiling insulation
Energy-efficient and sustainable
INDUSTRY NEWS
Eco-friendly building techniques remain high on local agenda BASF’s sponsorship of the Green Building Conference and Exhibition in Sandton from 24-29 July made sure eco-friendly building techniques remain high on the local agenda. BASF has brought several energy-efficient and eco-friendly products to market. BASF showcased insulation material Neopor, green roof technologies, Paint it cool!, concrete solution, Glenium, X-Seed for accelerated concrete hardening and the spray-applied polyurethane foam roofing system Elastospray. BASF has calculated in its climate balance that its products can save three times more greenhouse gas emissions than are produced during the manufacture and disposal of all BASF products. This effect is particularly significant in the construction sector where the 400 000 tons of insulating materials marketed by BASF worldwide in 2006 represent a total reduction potential of over 110 million ton of CO2. Lead-free alternatives BASF now offer new lead-free alternatives for the coatings industry – one of these is Paint it cool! These coatings absorb less solar radiation and lead to lower surface temperatures and reduced heat buildup. In warmer climates these ‘intelligent’ paints can decrease energy demand for air conditioners without affecting night-time comfort. Traditionally, red and yellow paint
78
colours have been provided by lead chromates and molybdates thanks to their durability, opacity and colour strength. From 2015, lead chromates and molybdates will be banned in Europe. BASF has developed a broad organic and inorganic pigment portfolio providing sustainable leadfree pigments. Thermal insulation Thermal insulation for buildings has received particular attention in recent years because of its potential for reducing energy demand. BASF’s insulation raw material Neopor, an expandable polystyrene with black beads, offers significantly greater insulation value and reduced raw material consumption compared to similar expandable polystyrene products. Neopor products can be used throughout the construction process, including interior and exterior insulation, flat roofs and pitched roofs, and for attic and basement ceiling insulation. By using Neopor, heating fuel consumption can be reduced on cold days, while reducing air conditioning demand on warm days. Green roofs Green roofs have gained popularity in recent years, allowing clients to use unused space. Green roofs are partially or completely covered with vegetation, planted over a waterproofing membrane. They can also include additional layers for drainage and irrigation where neces-
Traditionally, red and yellow paint colours have been provided by lead chromates and molybdates. From 2015 lead chromates and molybdates will be banned in Europe. BASF has developed a broad organic and inorganic pigment portfolio providing sustainable leadfree pigments
sary. Depending on the depth of soil, green roofs can accommodate trees, shrubs and bushes, but require more maintenance the deeper the soil. BASF has developed a number of technologies suitable for these green roofs. www.basf.co.za BASF has developed a number of technologies suitable for these green roofs
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
EQUIPMENT
®
Sphero 50 underwater pelletizing system from Maag WITH the new generation of the proven Sphero®50 underwater pelletizing system, Automatik Plastics Machinery will present an optimized adaptation of Maag’s single components at the Fakuma show in October. The Sphero 50 features a well thoughtout design and improved ergonomics. The technical benefits for the customer are quick start-up, permanent process reliability (even with difficult products) and an outstanding pellet quality. The operator benefits from the compact design, with all system components mounted on a mobile frame, as well as free access from all sides. Up to 600 kg/h With its modifications, the Sphero 50 can be especially applied in testing plants and technical centres as well as in smaller production plants with varied pelletizing application options for virgin polymers, masterbatches, compounds, technical plastics, recycling, thermal elastomers, micro-granular compounds and organic and timber-polymer materials. The unit can handle flow-rates of up to 600kg/h. In economic terms, even significantly lower flow-rates from approximately 70kg/h are already profitable (subject to product). ‘Plug & Play’ As the smallest system of the series, the design of the Sphero 50 ensures it can virtually be put into operation in a ‘plug & play’ manner. The entire system is mounted on a solid, mobile frame with lockable wheels and can be moved easily, adapted to other extruders, or ‘parked’ at an idle spot when not in use.
Quick product change for Masterbatch Applications: SPHERO®50 fulfils the special requirements of masterbatch applications because it is comfortable to use and important components such as die plate or dryer are easily accessible for cleaning with optimal matching filtration to boot.
All relevant pelletizer components such as start-up valves, die plates, water basins and drives are suspended from a T-bar, can be shifted on the bar horizontally, and can be accessed easily. All other system components such as the Centro 50 pellet dryer, the process water system, the hydraulic unit for the start-up valve, and the electric control cabinet with integrated touch panel are mounted to minimize the footprint while remaining freely accessible on the frame. Special attention was given to the new design of the cutter head to ensure the production of evenly shaped, high-quality
pellets. Thanks to the reset force-free adaptation of the blades to the die plate, the pellet quality is improved and process reliability is increased. • MAAG AND ITS PARTNER AUTOMATIK ARE REPRESENTED IN SOUTHERN AFRICA BY JOESTEN OF BRAKPAN. www.maag.com www.joesten.co.za
Filter drawer feature for Conair receivers Makes screen maintenance fast, easy THE new Filter-Drawer feature available on Conair DuraLoad vacuum receivers eliminates the need to remove the receiver lid to perform routine screen inspection and maintenance. Instead, a slim module, which can be fitted between the lid and the body of the receiver, features a slide-out drawer containing the filter-screen disc. To check, clean or replace the filter, users simply open two tool-free twist clamps and pull out the drawer. The Filter Drawer adds only 89 mm to the installed height of the receiver and is available in all popular Conair DuraLoad diameters. The Filter Drawer is available in stainless steel and in a special high-temperature version for when dried material is being conveyed at temperatures up to 171°C.
www.conairgroup.com 80 OCTOBER / NOVEMBER 2012
The UR-6-85-5-A is a small, light and user friendly 6-axis industrial robot. The robot comes with everything needed to program it
Automate your production easily, cheaply and flexibly UR-6-85-5-A
Gravicolor Gravimetric mixing and dosing units
MDE 120 Generator The dry air generator .
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office number
Please call for your local costal representative details and
email: jhb@plasquip.co.za www.plasquip.co.za
National Sales Number: +27 11 902 8923 FAX: +27 11 902 8980
Going to extremes in precision temperature control
Chen Hsong Holdings Ltd.
The high-end series combines the superior performance Ai-11 intelligent computer controller (built-in networking, intelligent diagnostic and on-line assistance) with hydraulic circuit optimized by the best European and Japanese expertise, resulting in even greater speed, shorter cycle times, significantly better control precision and unmatched ease-of-use.
The Jetmaster Ai-series of injection moulding machine with intelligent controls is the new flagship product line of the Chen Hsong Group.
MATERIALS
Durethan and Pocan for metal Freedom of design, ability to configure more complex geometries HIGHLY reinforced Durethan® and Pocan® high-modulus materials offer many different options for replacing diecast materials, such as aluminum or zinc. With a mechanical strength of up to 250 MPa, these materials exhibit strength properties equivalent to diecast aluminum. And, thanks to their considerably lower density, parts made from them can be made lighter with no loss of part performance, which once again leads to energy savings when they are in service. In addition, the greater freedom of
design and the ability to configure more complex geometries makes it possible to integrate components and their functions in a single part. In addition to reducing the need for further investments (such as tools and machinery) this can also bring down processing and assembly costs and cut down on potential sources of error. Further cost advantages are possible, because the finishing work frequently required for diecast parts is no longer necessary. Additional advantages include the highquality surface finish, paintability without
further pretreatment (if the component has not been produced in the desired colour already), and good resistance to chemicals and corrosion. Highly reinforced (high-modulus) grades for the substitution of metals Rising costs for energy and metals are increasingly necessitating more weight- and cost-efficient designs. Nowadays plastics more often replace metals. Due to this metal substitution not only weight can be saved but also an in-
High performance thermoplastic polymer powders LEHMANN & Voss & Co. of Germany, renowned as a producer of tailor-made high-performance compounds, is expanding its product portfolio to include thermoplastic materials in powder form, which are used as materials for coatings and laser sintering among other applications. The powder materials are applied as a thin layer on metal parts using conventional electrostatic coating systems. The strength of the metal components combined with the outstanding tribological properties of the powder compounds opens up an entirely new range of applications. Compared with conventional duroplastic an antifriction lacquer, wear resistance is increased by a factor of 10. The deep black surface produces a special appearance and is therefore also suitable for visible parts. Luvocom P 80-7858-B is the first product already being used in series. Lehmann & Voss & Co. now has laser sintering materials in its range as a second product line. Selec-
tive laser sintering is a generative production process with which plastic components are built up layer by layer without tools from a powder bed. During the process, a laser selectively melts the thermoplastics. The process draws the necessary data directly from the component drawing file. As a result, components with a complex geometry are literally created overnight. Lehmann & Voss & Co. produces and sells a laser sintering material under licence which is based on thermoplastic polyurethane (TPU) with the name Desmosint™ X92A-1. The components sintered from this are characterized by a combination of tensile strength, elasticity and wear resistance hitherto unachieved in laser sintering materials. In future, customized laser sintering materials will also be developed and sold for the consumer sector, electronics, automotive industry and many other industries to customer order and based particularly on
Desmosint™ X92A-1 – laser sintered TPU component
high-performance polymers. In cooperation with technology partners, work is additionally taking place on adapting laser sintering technology to the new materials. www.lehvoss.com
Technical focus!
Nissei ASB team in SA – Yvette Joubert (sales), Jaenine Krugell (admin & spares), Corne Pretorius (now heading the ASB South Africa office), Michelle Shanahan (accounts)
82 OCTOBER / NOVEMBER 2012
CORNE Pretorius is now heading ASB South Africa focusing on getting the technical support side strengthened to build good customer relations and support structure. Corne previously worked as production manager at Xacpet Wadeville and has seven years’ experience in PET production facilities. He joined ASB in 2001 as service manager with a total of 19 years’ experience in the PET industry. Corne says he has plans to improve customer support working with a strong technical team consisting of Jambo Sande, Ewoud Basson and John Becker as support engineers. Corne says ASB have opened a large mould manufacturing plant in India that will improve mould cost and delivery considerably, and ASB are planning to launch some new and exciting machine models soon.
substitution creasing number of functions can be integrated in an individual application. Since cost-intensive finishing work, like painting, has to be avoided wherever possible, this then leads to more stringent requirements being placed on quality and surface finish. With the high-modulus grades from its Durethan® and Pocan® product series, Lanxess is able to provide precisely the right solution here. Offering stiffnesses of up to 18,000 MPa and high strengths of up to 250 MPa, these grades attain values comparable with those of diecast materials and are thus eminently suited to the substitution of metals – especially for
Ampaglas achieves level 3 B-BBEE AMPAGLAS Plastics Group, the leading extruder of rigid plastic sheeting, has announced that it has successfully been audited by SANAS accredited company, Grant Thornton, securing the status of
Durethan AKV 325 H2.0 for special automotive applications – under the hood air tube
KEY ADVANTAGES: structural applications that are subject to a high level of stressing. Under certain conditions, expensive specialty polymers can also be replaced by Durethan® and Pocan®. Thanks to ultramodern and efficient material formulations, these materials with their high reinforcement levels of 50% to 60% can generally be processed just as easily as a general-purpose grade with 30 % reinforcement.
• high stiffness • high mechanical strength • potential for wall thickness reduction • good processability • better thermal conductivity, permitting earlier demoulding • less warpage • reduced thermal expansion • lower tendency to creep • good surface finish despite high filling levels • good chemical resistance • substitution of considerably more expensive plastics • suitable for replacing metals in structural components
www.plastichem.co.za
a level 3 Broad Based Black Economic Empowerment (B-BBEE) contributor. The new accreditation, which shows a marked improvement from the 2011 level 4 rating, is effective from 31 May. Notable achievements on the B-BBEE scorecard include the maximum scores for both enterprise and socio-economic development as well as a score of 12 out of a
possible 15 for skills development. “A score we are most pleased about is the score of 18 out of a possible 20 for ownership. Our business is 36.31% black owned and 4.43% black woman owned, percentages we hope to grow in the future,” says Ampaglas Plastics Group CEO Barry du Toit. www.ampaglas.co.za OCTOBER / NOVEMBER 2012 83
The Power to Create
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MATERIALS
Flowing safely BASF introduces plastics product line approved for drinking water BASF has now started offering a portfolio of engineering plastics specially designed for applications that come into contact with drinking water. The products from its Ultramid® (PA), Ultradur® (PBT) and Ultraform® (POM) lines that have been approved for drinking water will now bear the additional trade mark designation Aqua® in their names. Examples of this are Ultramid A3EG10 FC Aqua, Ultradur B4300G6 FC Aqua and Ultraform N2320 FC Aqua. The portfolio in the drinking water realm is complemented
by the proven and high-temperature resistant polyaryl sulfones Ultrason® P3010 and Ultrason S3010. The special requirements made of plastics that come into contact with drinking water include very low migration values, a high level of taste neutrality and confirmation that long-term contact with the plastic will not cause accelerated algae growth. The plastics in the Aqua portfolio have received all of the approvals for cold-water applications, and many of them also for warm and hot water. Cold water flows
through water meters and toilet flushing mechanisms, while warm water is by definition employed for showerheads and mixer faucets. Pipe fittings, for instance, are used in hot-water applications. In addition to complying with the regulations for food contact, the products to be used in the drinking water sector have to display much lower migration values. This means that BASF’s Aqua plastics generally also meet the requirements for use in contact with food. BASF can ALSO test customer´s compo-
New HPV provides high wear & abrasion resistance Improved sliding behaviour, high wear and abrasion resistance
Quadrant’s new TIVAR® HPV gives conveying systems a performance, cost and safety boost.
www.quadrantplastics.com
QUADRANT has launched the new TIVAR® polyethylene (PE) bearing grade, TIVAR HPV, to support improvements to the productivity and safety of conveying systems and a reduction in maintenance. TIVAR HPV is an ultra-high molecular weight polyethylene (UHMW-PE) developed specifically for wear components subject to challenging production environments, such as high speeds, high temperatures, high loads and aggressive cleaning agents. It is food contact compliant and available as semi-finished material and custom machined parts. TIVAR HPV has a built-in dry lubricant which gives it a Limiting Pressure Velocity value 18% higher than competitive material, resulting in reduced pressure sensitivity for finished parts. POM-C counterplate tests by Quadrant indicate that TIVAR HPV offers the lowest coefficient of friction value on the market, with a reduction of up to 80% in comparison to other UHMW-PE materials. As a result, components made with TIVAR HPV show improved sliding behaviour and high wear and abrasion resistance.
Tailored irrigation solutions Efficiency-focused material solutions BOREALIS and Borouge have unveiled Borstar® Aquility™, a new family of products for drip irrigation applications, initiated with the launch of pigmented Borstar Aquility HE3408 and un-pigmented Borstar Aquility ME3407 for thin wall pipe and tape production. Both of the new tailored PE materials optimize
productivity and rationalize costs for producers in the creation of water-saving, thin wall drip irrigation pipes and tapes. Borstar Aquility grades HE3408, a pigmented one-pack solution and ME3407, an un-pigmented single polymer solution ready for use with colour master batch, are solutions that eliminate the expensive step of blending multiple grades. The lack of a blending step avoids the risk of quality variations in the extruded pipe. In also helps to reduce material handling during the production process and simplifies inventory
management for pipe producers. The consistent, high melt strength and performance characteristics give producers the potential to achieve the high line speeds and thin walls requested by the market for thin wall pipes and tapes. The materials’ easy weldability complements commonly used in-line dripper insertion technologies and is compatible with high speed production operations. www.borealisgroup.com
Borstar Aquility tailored for drip irrigation applications 84 OCTOBER / NOVEMBER 2012
nents made of the new group of plastics in its own flow laboratory. This is where water meters, pipe fittings and other parts that carry drinking water can be tested for their long-term resistance against chlorinated water at various temperatures, pressures, pH values and flow rates over the course of thousands of hours. The flow tests can be followed by burst pressure tests or other customer-specific examinations. www.basf.de/ultras
BASF is now offering a comprehensive product portfolio of engineering plastics that are approved for contact with drinking water. (PHOTO: GROHE)
Novopearls microbatch for plastic coloration Novopearls now available in small batches and can be mixed with liquid colours 2011, the gap between liquid colours and conventional batch granulates has been filled by Novopearls micro-granulate. For the first time it has been possible to use the positive characteristics of liquid colours with higher levels of coloration (liquid colours max. 3% filling volume) while simultaneously reducing the amount of batch material added. The liquid carrier can also have a positive effect on surface quality. The spherical micro-granulate with an average diameter of 450μm is made up of a wax composition which can be extremely well homogenized with numerous plastics. Novopearls are highly pigmented, can be mixed together and have excellent flowability. A big bonus is the melting point of the micro-granulate of just 85°C. The microgranulate melts in the moulding machine faster than the plastic to be coloured. This results in a rapid, streak-free homogenization of the colour and the plastic, previously only achievable with liquid colours. According to Novosystems, bulk plastic
Dosing - Novopearls micro-granulate with the characteristics of liquid colours. Novopearls can be used on their own or in combination with liquid colours
Product example: Extrusion profile (COURTESY OF BOLTA)
materials such as PVC, PS and other technical plastics can be coloured with the micro-granulate. As a result of optimally dispersed pigments in the wax-based granulate very small amounts of additives between 0.1% and 0.9% are possible. www.novosystems.de
OCTOBER / NOVEMBER 2012 85
THE new Novopearls micro granulate is rapidly becoming a best-seller for Novosystems, the coloration specialists from Seevetal, Germany. In addition to excellent homogenization and coloration performance, it is now possible to order smaller batches. Previously, minimum orders were approx. 1 000 kg per batch and were mainly deployed for extrusion; now batches as small as 100 kg are available. Customers have been using the product in a number of applications, resulting in accumulated practical experience in mixing Novopearls with liquid colours. In the case of very thin-walled products for the packaging industry, using Novopearls can result in further increases in coloration (chromaticity). In general, Novopearls as a solid possess the characteristics of liquid colours, make additional increases in coloration possible and offer cost-savings in comparison with conventional colour batches. Since its launch at the Fakuma fair in
MATERIALS
First electric car charging stations with PU housings
Bayer MaterialScience and Solid Composites GmbH are partnering to develop thermoplastic polyurethane (TPU) powders for selective laser sintering.
Profitable production even in small numbers SPANISH firm Ingeteam has developed charging stations for electric cars in close collaboration with Bayer MaterialScience and Policam. For the first time ever, the housing is made of polyurethane: robust Baydur® 110 rigid polyurethane foam. Two different versions of the charging stations are available: one suitable for outdoor installation along public roads and on plazas, and a wall-mounted model for installation in private homes. More than 500 prototypes of the charging stations have already been installed at Spanish supermarkets, parking garages, conference and exhibition centres. So far the charging stations are available only in Spain, but expansion to other countries and continents is possible. “This development is another example of how Bayer MaterialScience develops solutions for future mobility concepts,” says Alp Sarici, a marketing expert for polyurethane systems. “Unlike other plastic solutions, the polyurethane housings can also be produced profitably in small numbers, not least because the moulds are relatively inexpensive.” Spanish firm Ingeteam has developed charging stations for electric cars in close collaboration with Bayer MaterialScience and Policam. For the first time ever, the housing is made of polyurethane: robust Baydur® 110 rigid polyurethane foam. The model shown here is suitable for outdoor installation along public roads and on plazas
www.policam.cat www.ingeteam.com www.materialscience.bayer.com 86 OCTOBER / NOVEMBER 2012
Major potential for short-run production and customized products BAYER MaterialScience and Solid Composites GmbH are partnering to develop thermoplastic polyurethane (TPU) powders for selective laser sintering. This innovative method for fabricating three-dimensional structures is based on the use of a laser beam to sinter powdered starting materials. The start-up company based in Voerde, on the Lower Rhine, will be awarded a brand license to market the new high-tech materials under the name Desmosint. This opens the door to numerous potential applications, for instance in the automotive industry, in sports goods, robotics or aerospace engineering. Solid Composites is a spin-off of the Fraunhofer Institute for Environmental, Safety and Energy Technology (UMSICHT). “Solid Composites has made a name for itself as a creative developer and supplier of thermoplastic powders for laser sintering and electrostatic coating, among other things, and is therefore the partner of choice for us when it comes to successfully marketing our TPU innovation,” explains Jürgen Hättig, TPU marketing specialist at Bayer MaterialScience. No moulds necessary Selective laser sintering is becoming a firmly established digital manufacturing method in the additive manufacturing of plastic parts. A part is made from a thermoplastic powder based on the part’s structural design data. Guided by CAD software, a laser fuses successive layers of a powder bed at selected points where the part is to emerge. In other words, the part ‘grows’ layer by layer. Until now, primarily soft, elastic materials and rigid thermoplastics, such as polyamide, were commercially available for selective laser sintering. “Our TPU products, with their high toughness, elasticity and strength, have now closed the gap between these material classes. And that opens the door to good application opportunities,” Hättig says. The first representative of the new class of TPUs is Desmosint X 92 A-1. One of its advantages is that the space in which the TPU is processed layer by layer must be maintained at a temperature of only 80°C, in contrast to polyamide, for instance, which is processed at slightly below its melting temperature. Selective laser sintering typically offers great design freedom and is particularly suited to the additive manufacturing of short to extremely short runs, for instance in the production of components like housing parts, bellows and hoses for full-size and luxury sedans. When used with the TPU products, the method also is ideal for producing custom components, such as orthopaedic shoe inlays, athletic shoes, helmets and prosthetic devices. www.solidcomposites.de www.materialscience.bayer.com
Deepening the value chain of the chemical sector Many companies within the chemicals sector and sub-sectors are currently reporting increased demand for products due to improved economic conditions. This is driving increased activity for the IDC’s Chemical and Allied Industries Unit, which invests in projects in a number of chemical industry sub-sectors across the value chain. From fertilisers, to detergents; disinfectants and packaging, South African consumers are the end beneficiaries to many industries within the chemicals sector. The Unit concentrates on the manufacturing of base chemicals, including oil and gas, plastics and rubber, cement and concrete, cosmetics, glass and ceramics. Projects that have the potential to develop new industries, lead the expansion of existing ventures, or replace the need to import materials, are a key focus. The strategic objective of the Unit is to deepen the value chain of the chemicals industry sector, including the security of supplies for key inputs into infrastructure, food and energy needs. The Unit will target investment of more than R7bn over the next five years, into sub-sectors that include polymer conversion, water treatment chemicals, agriculture products, infrastructure-related materials, speciality and fine chemicals, and rubber products.
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Prime examples of the Unit’s investment into the chemicals sector can be seen in mining company Foskor, initially founded by the IDC in 1951; Bliss Chemicals (Pty) Ltd, which ch is
Telephone: 086 069 3888 Email: callcentre@idc.co.za To apply online for funding of R1 million or more go to www.idc.co.za
the manufacturer of MAQ detergent; ITB Manufacturing, award-winning plastic film packaging manufacturers; and BTC Products and Services (Pty) Ltd, a leading South African manufacturer and distributor of Chlorine Dioxide (CD) that ensures safe drinking water. The Unit was involved in the introduction of Broad-Based BEE groupings into Foskor, which resulted in IDC’s shareholding reducing from 85% to 59%. The company continues to provide a domestic source of fertilisers and supports the sustainability of local agriculture. Bliss Chemicals (Pty) Ltd, a relatively young company has, with financial assistance from the Unit, been able to diversify their popular MAQ detergent and extend their product offering. MAQ washing powder currently has a 25% share of the detergents market. ITB Manufacturing, located in the municipality of eNdondakusuka between Durban and Richards Bay, is involved in a number of social initiatives in the economicallystricken surrounding area. The Unit has financed a financial services and human resources consultancy company via a SPV structure, to addresss the th shortage of equipment and resources. BTC Products oduct and Services (Pty) Ltd, with funding from the IDC, DC, ha has been able to develop its OXICAT Chlorine Dioxide de technology te that provides a number of innovations to o treat tre water for safe drinking.
MATERIALS
Keeping a firm grip KRAIBURG TPE compounds ensure a steady hand for sharp, clear pictures. Precisely dimensioned TPE ‘mats’ serve as reinforcement material for the grips of the Leica S2 camera and the Ultravid binocular series. These high-quality products are manufactured using Thermolast® A from Kraiburg TPE of Germany. The TPE is pleasant to the touch and highly scratch resistant. Leica’s in-house testing processes, developed based on customer applications, confirm that the grips made of the Kraiburg TPE compounds withstand all effects of daily use, such as perspiration, alcohol and atmospheric conditions. Nor does the photographer have to worry about ill effects, since the TPEs are free of polycyclic aromatic hydrocarbons, phthalates and allergens and are RoHS and REACH compliant.
Elastomers used on grip of The reinforcing mats are manufactured Leica’s cameras perform in a single-component process and then exceptionally well glued into recesses specially moulded in the casing. The depth of the recesses varies depending on the shape of the casing and therefore affects the thickness of the TPE layer. In cooperation with Leica, Kraiburg developed solutions for tool design and application engineering. “We received sample material early on, in addition to useful information for the prototyping process, which enabled us to start production very quickly. Gluing of the grips was a high-precision www.leica.com process,” said Oliver Neumann, a production planning www.kraiburg-tpe.com specialist at Leica.
Pioneering NorCell technology High quality film products for food & hygiene NORDENIA of Germany is the first packaging company to successfully implement Nor®Cell technology in flexible packaging. The multinational film manufacturer and converter is meeting the demands of the growing importance of the topic of sustainability and resource conservation. Nor®Cell technology reduces the weight of flexible packaging by using a physical, controlled foaming process without reducing the film thickness. This lightweight construction film weighs up to 40% less than conventional film.
Packaging made with Nor®Cell is characterized by a high puncture resistance, excellent sealing ability and great printability. This therefore meets all of the customer requirements for high quality, flexible product packaging. Another advantage: the reduced packaging weight is also noticeable as a saving for the customer with the transportation costs and also later with the disposal charges. The technology pioneer Nordenia is active throughout Europe as an exclusive contact for all matters relating to Nor®Cell
With Nor®Cell technology (see film cross section on the right side of the photo), surface structures with unique haptic properties are realized in a controlled foaming process – they noticeably differ from the bumpy surfaces of conventionally foamed films (see film cross section on the left side of the photo)
technology for flexible packaging. In combination with the well-founded expertise of Nordenia, high quality packaging is currently being produced for the food, petcare, wet wipe, detergent and hygiene. Nordenia worldwide Nordenia International AG is a multinational manufacturer of flexible packaging, technical films and product components. Core competencies include manufacturing, printing, coating and processing of highquality films. As a leader in innovation and technology, the Nordenia Group has an outstanding market position. The products are used in a wide variety of areas, in particular in the endmarkets Hygiene, Converting Fast Moving Consumer Goods (FMCG), Food, Petcare & Garden, Beauty & Healthcare / Detergent & Cleansing Agents and Industrial. Nordenia employs around 3,000 people worldwide. The shared values serve as the foundation for their activities. With its seven shared values of Flexibility, Global, Independence, Innovation, Partnership, Passion for Excellence and Quality, Nordenia has a partnership-oriented company culture. www.nordenia.com
88 OCTOBER / NOVEMBER 2012
the art of colour At the intersection of art and science, you’ll find MBSA C
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Masterbatch SA creates, manufactures and supplies masterbatch, pigments and performance enhancing additives to the plastics industry.
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MBSA’s products stem from a deep appreciation for art and a passion for creating colour in a responsible manner. That’s why MBSA is the only South African masterbatch manufacturer to hold all ISO accreditations for food safety, health & safety, environmental and quality management systems.
Johannesburg 011 975 0222 Cape Town 021 552 0627 KwaZulu Natal 031 700 2464 Port Elizabeth 083 974 2074 East London 083 282 8850
MBSA takes pride in investing in local talent, promoting some of South Africa’s most promising artists and their projects.
info@masterbatch.co.za www.masterbatch.co.za
Contact MBSA for your colouring needs. We guarantee to match your expectations.
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ISO 9001: 2008 ISO 14001: 2004 OHSAS 18001: 2007 ISO 22000: 2005
‘Goldfish’ 2012 by Neil Pauw of The Parlotones
MATERIALS
Carbon fibre recycled from aircraft production delivers aesthetics Boating blades from carbon fibre reinforced plastic look as good as they perform WERNER Paddles of Washington state, USA, a manufacturer of fine handcrafted boating paddles, has always combined the most advanced technologies and features to bring out the best paddle performance. When they began having aesthetic issues with their smooth, jetblack kayak paddle blades, they moved quickly to find a solution. The blades made from carbon fibre reinforced plastic are designed to look as good as they perform. “The carbon fibre compound Werner used for the blades is more commonly found in the manufacture of structural components where surface quality is not a priority,” said Tim Bailey, engineering manager of Werner’s moulder, KASO Plastics of Vancouver, WA. “For Werner, the cosmetics of the material were as important as the strength, rigidity, and other physical properties.”
The challenge was to find a way to deliver both performance and aesthetics. Bailey and his engineering team tried upwards of a dozen different materials from several suppliers without success until they connected with custom compounder RTP Company who recommended a recycled content material. The material, a carbon fibre reinforced compound, was developed by RTP Company with assistance from aircraft manufacturer Boeing who introduced them to the Aircraft Fleet Recycling Association (AFRA), an emerging composite recycling network that Boeing helped establish. AFRA looked to RTP Company for high-end applications
www.rtpcompany.com www.wernerpaddles.com
www.kaso.com
to use carbon fibre reclaimed from manufacturing scrap from the 787 Dreamliner airplane production. The premium, aircraft grade carbon fibre delivered the physical characteristics required at a lower fibre loading, allowing KASO to meet aesthetic requirements, something none of the virgin materials were able to do. In addition, the material is actually a little bit easier to process, and the system cost between the recycled content carbon fibre compound and virgin alternatives is insignificant.
Werner’s kayak paddle is a great example of Boeing’s sustainable manufacturing strategy at work, where post-industrial scrap from aircraft production provides a high-performance solution for a consumer product
Ultramid Balance in quick connectors for fuel lines Hydrolysis resistance, high resistance to fuel
Polyamide (PA) 6.10 from BASF can be used in quick connectors for fuel lines
THE new 30% glass fibre-reinforced Ultramid® S3WG6 Balance has found a production application at A.Raymond, the internationally active automotive supplier of fasteners and connectors with headquarters in France. Here it uses the polyamide (PA) 6.10 from BASF that was first introduced at the K 2010 in quick connectors for fuel lines. The material is characterized by not only its hydrolysis resistance, but also its exceptionally high resistance to fuel. The mechanical properties after storage for over 2,000 hours at elevated
Compostable bubble wrap CARDIA Bioplastics has launched the Cardia Compostable Bubble Wrap, extending the product range made from Cardia’s certified compostable resins into protective packaging. Cardia Compostable resins are proprietary high performance materials that deliver packaging products of excellent mechanical strength, outstanding elongation properties and toughness. They are independently certified biodegradable and compostable to Europe EN13432, USA ASTM D6400, Australia AS4736, and Japan Green Pla standards. The new Cardia Compostable Bubble Wrap is destined for the European market.
90 OCTOBER / NOVEMBER 2012
www.cardiabioplastics.com
temperatures in biofuels such as E 24, B30, or B100, for instance, are at a level comparable to those of PA 12 GF 30. The material also passes the typical automotive tests for environmental stress cracking resistance in the presence of zinc chloride (SAE 2644, FMVSS 106). As a consequence, the material is able to replace PA 12 in applications where this is required. Quick connectors of this kind are used by almost all major global automobile and truck manufacturers. www.basf.com
Extraordinary Colours
153 Haring Road Wadeville Ext 2 21 YEARS Established 1990
For all your colouring requirements of masterbatch and pigments. We have the latest computerised colour matching facilities and 21 years expertise.
Impossible just won’t do!
DEKRA EN ISO 9001:2000 CERTIFIED
Johannesburg: Tel: (011) 824 0350/1/2 • Fax: (011) 824 0353 • email: aussie@mercuryplastics.co.za Durban: Conrad Pillay 082 358 4727 • Cape Town 021 552 4433 •
MATERIALS
Perspex SA & XPS Two companies, one vision Manufacturing capacity moved to Lucite world-class facilities in UK
IN THE DYNAMIC world of Perspex South Africa, change is the only constant. Following on from the launch of Xtruded Polymer Solutions (XPS), the Port Elizabeth-based rigid plastic sheet extrusion facility, in October 2010, the group has been hard at work reviewing its overall business model and value offering to the marketplace. Once the XPS manufacturing facility was bedded down and producing top quality styrenic and polyolefin-based sheet products, the management team at Perspex SA began to review and analyze their Perspex cast acrylic sheet manufacturing facility in Durban. In order to supply the market on a long-term, sustainable basis with world class acrylic sheet at competitive prices, the decision was taken to shift the manufacturing capacity to the world-class facilities of Lucite International in the UK.
This presented several exciting opportunities for Perspex SA as Lucite is one of the world’s largest cast acrylic sheet manufacturers, with access to global technologies and product innovations. Perspex SA is now able to exclusively offer the trusted Perspex brand, made to world-class quality standards. Furthermore they have access to dynamic new products such as the visually stunning Perspex ‘Coral’ range and futuristic Perspex ‘Spectrum LED’ range designed with the LED lighting market phenomenon in mind. Xtruded Polymer Solutions (XPS) The XPS business is rapidly establishing itself as a manufacturer of top quality ABS, HIPS, HDPE and PP sheeting for the printing, POS, vacuum forming and fabrication industries. For those clients looking for extruded acrylic medium impact
Perspex SA is now able to exclusively offer the trusted Perspex brand, made to world-class quality standards (MI) and ultra high impact (UHI) acrylic sheeting, XPS also offers this solution as a traded product. XPS leverages off the national footprint of sales, technical services, distribution and warehousing facilities within the Perspex SA stable and carries significant stock levels around the country to offer its client base a JIT-based service offering second to none. XPS sets itself apart by focusing on specialized markets and offering a full technical, sales and partnership based value offering to these markets rather than just being a vanilla, commodity based sales organization. This focus has resulted in some fantastic long term partnerships being forged. Perspex South Africa (PSA) After the exciting metamorphosis, the quality of the Perspex product now offered by PSA is vastly improved and this presents several opportunities for fabricators, sign makers and POS manufacturers to now
92 OCTOBER / NOVEMBER 2012
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Lanxess to build worldâ&#x20AC;&#x2122;s largest EPDM plant in China
160 000 tons per year
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use cast acrylic Perspex based on a ďŹ&#x201A;atter sheet proďŹ le not too dissimilar from extruded acrylics, while still retaining all the premium qualities of a cast acrylic product. Furthermore, Perspex SA can now offer the Spectrum LED Perspex range which diffuses LED backlit lighting to avoid â&#x20AC;&#x2DC;hotspotsâ&#x20AC;&#x2122; and also enhances the resulting colours of the material. The Perspex Coral range is inspired by the 3D effects of coral reefs and offers several design opportunities for architectural, shopďŹ tting and POS applications. Adding to the basket of goods, Perspex SA now also offers the â&#x20AC;&#x2DC;Polygalâ&#x20AC;&#x2122; brand of multi-wall polycarbonate sheeting which is growing in popularity due to the superior thermal properties offered by this material. The future The dynamic business culture of both Perspex South Africa and XPS means that both these businesses will constantly evolve in conjunction with their client needs and market dynamics. More new product lines will be introduced to add to the basket
of goods the market can source going forward. New and innovative ways will be developed to satisfy the markets demands and changing material and service requirements. By developing close working relationships and listening to clientsâ&#x20AC;&#x2122; needs, these two companies with one shared vision will be able to stay one step ahead of the pack.
www.perspex.co.za
LANXESS is building the worldâ&#x20AC;&#x2122;s largest plant for EPDM synthetic rubber in China, investing â&#x201A;Ź235 million in the plant in Changzhou (Jiangsu Province). This is the largest investment the company has made in China to date. The plant will have a capacity of 160 000 tons per year and the investment will create up to 200 new jobs. The plant is expected to start up 2015. Lanxess is the worldâ&#x20AC;&#x2122;s leading supplier of EPDM following the successful acquisition and integration of DSM Elastomers in 2011. It markets its products under the brand name Keltan. Global demand for EPDM is expected to increase by more than 4% per annum in the coming years, while demand in China is expected to grow by around 8%, driven above all by automotive and construction industries. China will also continue to be the largest net importer of EPDM in the coming years. www.lanxess.com
www.extruded.co.za OCTOBER / NOVEMBER 2012 93
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FEATURE
Cash low is King – Credit management is key
PART TWO
BY PAUL JOOSTE, COFACE SOUTH AFRICA ability to stay in business and grow. As a FOLLOWING the global recession and result, effective cash and working capital current economic uncertainties, companies management have become a strategic across the board have faced increasing priority. competition, decreased demand, strong The following steps can be taken to downward pricing pressure and restricted shorten the cash flow conversion period and expensive access to credit. and will go a long way towards eliminating As any credit squeeze will affect the dangerous cash flow gaps. market or a particular economic sector, suppliers need to ensure that invoices Cash flow projections are paid on time. This can put pressure on smaller companies, especially those Prepare cash flow projections for the who may be vulnerable since they cannot next year, next quarter and even next employ dedicated resources to collect week. Start by adding cash on hand outstanding amounts for debtors. at the beginning of the period with Cash flow difficulties are without a doubt other cash to be received from various negatively affecting many companies’ daysources. Know the amounts and dates of to-day operations. External stakeholders, the required cash outlays for the period. such as banks, are looking for evidence Consider potential scenarios and plan that firms are for them. For actively improving example - if suchWeed out unprofitable their working capital and-such happened customers, those that cost by cutting costs and your predicted more to maintain than they and managing their cash flow dropped add to the bottom line inventory better x%, what could before granting or you do? extending credit. Monitor your cash flow to forecast Cash flow has therefore become potential cash flow problems and take more critical than ever to a company’s steps to remedy them. One of the
94 OCTOBER / NOVEMBER 2012
easiest ways to monitor cash flow is to compare your company’s total unpaid purchases to the total sales due at the end of each month. If the total unpaid purchases are greater than the total sales due, you will need to spend more cash than you receive, indicating a potential cash flow problem. Know your customer It goes without saying that a proactive approach to credit management is important. Some of the following suggestions can be implemented: Cash flow controls should be evaluated by reviewing your credit policies on an ongoing basis. Trade credit must be based on a formal document, such as an appropriate credit application form. Credit terms must be set at the onset and should appear in writing on statements and invoices. It is important to know the financial position of the company you are trading with. Your internal credit procedure should include an upfront stringent credit vetting process and credit should only be given to clients who are creditworthy and considered to be long-term business partners. Investigation should include basic credit checks. For example - trade and bank references, and depending on the value of the credit facility, the client’s business plan and financial statements. This can be handled by a credit insurer, or alternatively you can purchase information reports which generally contain the majority of the required information on the debtor. No credit applicant should expect to be granted a credit facility without providing adequate guarantees. A client’s failure to provide such information ought to throw a negative reflection on the application. Require all sales and financial
management staff to know and follow credit policies. A beneďŹ t of a credit insurance policy is that debtor payment information is gathered from all policy holders. The credit insurer is therefore well placed to pick up early warning signs such as defaults or extended payment terms to one or more suppliers. Regularly identify and address any possible early â&#x20AC;&#x2DC;warning signsâ&#x20AC;&#x2122; which may trigger future payment problems, for example: a. Postdated cheques issued b. Dishonoured cheques issued c. Change in banker d. Changes in payment pattern e. Low stock levels f. Signatories away from the ofďŹ ce for long periods g. DifďŹ culties in reaching the debtor by telephone h. Failure to return calls i. Lack of ďŹ ling of accounts as required by the Registrar of Companies j. â&#x20AC;&#x2DC;Trust your gutâ&#x20AC;&#x2122; Managing your customersâ&#x20AC;&#x2122; credit is an important part of cash ďŹ&#x201A;ow management. Weed out unproďŹ table customers, those that cost more to maintain than they add to the bottom line. Flag those who have a history of slow payment. Remember that you do not have to extend credit to anyone. If a customer has a history of slow payment, changing the credit terms or even eliminating credit entirely may be necessary. In an environment where demand is low and competition is high, the age old saying, â&#x20AC;&#x153;A sale is not a sale until the money is in the bank,â&#x20AC;? is still important.
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ABOUT COFACE The Coface Group, a worldwide leader in credit insurance, offers companies around the globe solutions to protect them against the risk of ďŹ nancial default of their clients, both on the domestic market and for export. In 2011, the Group posted a consolidated turnover of â&#x201A;Ź 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 companiesâ&#x20AC;&#x2122; 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 â&#x201A;Ź 16.4 billion end December 2011. In South Africa, Coface provides credit protection to clients. Coface South Africa is rated AA+ by Global ratings.
OCTOBER / NOVEMBER 2012 95
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BOOKS
Ceresana analyzes the adhesives market MARKET RESEARCHERS FROM CERESANA EXPECT A REVENUE OF ALMOST US$50 BILLION FOR THE GLOBAL ADHESIVES MARKET IN 2019. Especially the dynamic economic development in emerging countries such as China, India, Russia and Brazil will stimulate further growth in demand for adhesives. The market research institution expects demand to rise by 2.9% p.a. in the next eight years, meaning that growth will even accelerate when compared to the last eight years. The major product group is adhesives based on vinyls. Almost 3.5 million tons of this types was demanded worldwide in 2011. An above-average growth of more than 3% p.a. is expected for the demand
for acrylics-based adhesives in the period from 2011 to 2019. More than half of the adhesives demanded on a global level in 2011 were water-based - a continuing increase of demand in the next eight years is forecast, as more and more solvent-based adhesives are replaced by other technologies. Changes due to ecological aspects will have effects on both the production processes of adhesives as well as on further substitutions of various types of adhesives. The study summarizes the most
Popular plastic CERESNA expects a dynamic growth of worldwide revenues generated with polypropylene (PP) to amount to more than US$145 billion in 2019. Especially the dynamic economic development in emerging markets will continue to boost demand for PP. The average annual growth rate of 4.4% in the last eight years is likely to be surpassed in the future, as is explained exhaustively in the market study recently published. The study is a concise overview of the different production methods and processing techniques of PP and provides the most important information on PP’s characteristics, application areas, recycling possibilities, disposal options and legal situation. The study also provides in-depth analyses on demand, production and capacities, as well as revenue and price development. Countries are analyzed in detail: PP demand, revenues, production, and imports & exports during past eight years are described. The application areas of PP, for example flexible and rigid packaging, fibres, automotive industry, electrics and electronics, consumer goods, construction industry and other application areas are analyzed thoroughly. Data on demand development, split by Western Europe, Eastern Europe, North America, South America, Asia-Pacific, the Middle East, and Africa as well as consumption figures for specific regions are also given. The study also contains a useful list of producers that provides profiles of PP manufacturers – clearly arranged according to contact details, turnover, profit, product range, production sites, profile summary, and capacities. www.ceresana.com/en/market-studies/plastics/polypropylene
96 OCTOBER / NOVEMBER 2012
important facts about various types of adhesives, offers a depiction and an analysis of the global adhesives market, discusses revenue generated with adhesives, the fields of application, examines the demand regarding different processing technologies, as well as offers profiles of the major producers of adhesives, clearly structured by contact data, revenue, profit, product range, production sites, profile summary and product base. www.ceresana.com/en/marketstudies/industry/adhesives-world
Updated report on global solvent market THE market experts from Ceresana forecast the global solvent market to earn revenues of about US$33 billion in 2019. Especially the dynamic economic development in emerging countries like China, India, Brazil, or Russia will continue to boost the demand for solvents. The market research institute expects worldwide solvent consumption to increase at an average annual rate of 2.5% over the next years. Accordingly, the growth rate seen during past eight years will be surpassed. The most frequently used solvents are alcohols, such as ethanol, n-butanol, isopropanol, and methanol. About 6,4 million tons of alcohol-based solvents were used worldwide in 2011. Demand for ethanol and ethers is projected to rise at an above-average growth rate of more than 3% per year between 2011 and 2019. Demand for halogenated solvents is especially declining in Western Europe and North America. Also aromatics and pure hydrocarbons will continue their downward trend. Amongst other things, the most comprehensive report worldwide analyzes how the use of solvents will develop in individual markets. Most important buyers include producers of paints and coatings. They are followed by a considerable distance by printing ink manufacturers: The printing ink industry accounted for somewhat more than 8% of global solvent demand in 2011. The pharmaceutical industry came in third place, followed by cosmetics and adhesives. Furthermore, solvents are used in a broad variety of other industrial applications, for example in chemical manufacturing processes, cooling circuits, chemical dry-cleaning, and as de-icing agents. www.ceresana.com/en
WORLD NEWS
Rhodia Acetow ‘Accoya’ wood technology ACCSYS and Rhodia Acetow GmbH, member of the Solvay Group, have signed a licence agreement for the production and sale of Accoya® a high performance modified wood, based on Accsys’ cutting edge acetylation technology. It converts sustainably grown softwoods and non-durable hardwoods into ‘high technology wood’. This conditional agreement is expected to be fully effective in the second half of 2013 provides Rhodia Acetow the exclusive rights to sell Accoya in over 40 European countries for a 15-year period.
The agreement allows Rhodia Acetow the construction of multiple Accoya production plants, with the first plant intended for an initial capacity of approximately 63,000 m³ of finished Accoya output that should become operational by year end 2014. Rhodia, as one of the world’s leading producers of cellulose acetate, a material which shares certain processing components with our Accoya technology, also have the technical knowhow and expertise which should further contribute to the success of this licence.
Accoya® decking, cladding and structural beams were used in the construction of this house and boathouse, The Haven, Norfolk, UK
• RHODIA IS REPRESENTED BY PLASTOMARK IN SA • SOLVAY IS REPRESENTED IN SA BY SOLVAY POLYMERS & CHEMICALS OF PRETORIA www.accoya.com www.accsysplc.com
New EPSRC industrial doctorate centre in composite manufacture
The Industrial Doctorate Centre (IDC) has attracted new funding of £3.8m from the UK Engineering and Physical Sciences Research Council and aims to provide the composites manufacturing industry with elite research engineers
A vintage Fender guitar with a clear advantage A ONE-of-a-kind Fender guitar is up for sale – a prototype from 1972 that’s made from plastic. Built by Fender luthier Roger Rossmeisl, the guitar features a contoured Perspex body, black anodized hardware and a Starcaster-style neck. It was used by Carl Wilson when he was recording the Beach Boys’ 1973 album Holland and he retained ownership of the guitar for many years. This wasn’t the first plastic guitar made by Fender – a clear Stratocaster was produced for publicity purposes in the 1950s. The guitar is being sold on eBay by the Los Angeles Guitar shop for $29,999.99.
A NEW activity integral to the EPSRC Centre for Innovative Manufacturing in Composites (EPSRC Centre) will be supporting over 30 EngD programmes of four years duration, where selected research engineers will undertake specialist training and conduct an industrially focused research project, spending 75% of their time at a company. The Industrial Doctorate Centre (IDC) has attracted new funding of £3.8m from the UK Engineering and Physical Sciences Research Council and aims to provide the composites manufacturing industry with elite research engineers equipped with the necessary advanced technical and leadership skills required for effective adoption of new knowledge and technologies in composites manufacture. The IDC will have its base at the UK National Composites Centre in Bristol, with access to a complete range of equipment and techniques required for composites manufacturing research. It is open to all UK industry and academia and will eventually offer wide access to its bespoke taught modules. www.epsrc-cimc.ac.uk
ZL Engineering Plastics unveils new stock shape manufacturing facility ZL Engineering Plastics Inc., manufacturer of high-quality thermoplastic stock shapes, has started up a new extrusion facility at its Lenexa, Kansas, site in the USA in response to growing North American demand for its extensive range of stock shape products. The new production capability is the first phase of a strategic plan to grow the stock shape business in North America. Previously, stock shapes were manufactured in Kaprun, Austria, by ZL Engineering Plastics’ parent company, Zell-Metall GmbH Engineering Plastics. ZL Engineering Plastics has enjoyed strong growth over the last several years by providing high-quality materials and superior customer service. The company manufactures sheet, rod, and tube made of a range of engineering thermoplastics including nylon, acetal, polyethylene terephthalate (PET), polyetherimide (PEI), and polyetheretherketone (PEEK). These materials meet the demanding requirements of fast-growing end-use markets including aerospace, medical, automotive, semiconductor, agriculture, food processing, and construction.
www.zlplastics.com 98 OCTOBER / NOVEMBER 2012
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2012/09/17 2:57 PM
Sortex powers ‘green bottle’ drive in UK
WORLD NEWS
UK recycler and Coca-Cola joint venture opts for SORTEX to help the soft drinks giant achieve its recycling targets ECO Plastics is one of the United Kingdom’s leading reprocessors of postconsumer plastics. It set up a joint venture with Coca-Cola Enterprises in February 2011 aimed at boosting recycling of PET bottles. The new venture, called Continuum Recycling, uses ECO Plastics’ groundbreaking reprocessing plant at Hemswell in Lincolnshire as its main base. The plant has just undergone a £15-million expansion and now has the capacity to process up to 150,000 tons of plastic bottles a year (that’s about two billion 2-litre plastic bottles), making it one of the world’s largest and most technologically advanced facility of its kind. It now produces an additional 25,000 tons of high-quality rPET a year, on top of the 15,000 tons it previously produced. This will be enough to ensure Coca-Cola Enterprises can reach its target of including 25% of recycled plastic material in all its plastic packaging in 2012. Greater volumes To achieve this important environmental goal, greater volumes of PET (polyethylene terephthalate) flake must be sorted at Hemswell, which is why ECO Plastics has added an additional Sortex A5 optical
AROUND THE WORLD LANXESS DEVELOPMENT CENTRE IN HONG KONG LANXESS is strengthening its ties with automotive customers in the growing Asia-Pacific region. The specialty chemicals company will open a new application development centre in the Hong Kong Science & Technology Park in the second half of 2012. The new centre will have computer aided development and engineering facilities, as well as a parts testing centre, focusing on the company’s high-tech plastics Durethan and Pocan. www.lanxess.com
STRATASYS & OBJET COMBINE STRATASYS Inc. (NASDAQ: SSYS), a leading manufacturer of 3D printers and production systems for prototyping and 100 OCTOBER / NOVEMBER 2012
sorter to its facility. The company first invested in the Sortex Z+ in 2008, and has now added a brand new five-chute model – capable of sorting up to six tonnes per hour – to its Lincolnshire site to work alongside the Z+. ECO Plastics uses Sortex technology to remove unwanted colour, glued flakes and foreign materials (including wood, aluminum and other metals) from clear and clear blue PET. Sortex offers world-beating solutions said Buhler representative Alex Vaks: “It determines the purity of input product with exceptional accuracy within a split second. Foreign materials are identified on the basis of colour, shape or other optical properties, and removed from the product stream. “State-of-the-art technology makes the Sortex range breathtakingly accurate. Extremely high-resolution cameras detect the product defects and foreign matter. Optional InGaAs cameras can detect and differentiate between a diversity of foreign materials based on invisible optical properties. Optional PROfile technology identifies product defects through a combination of various parameters such as shape, size and colour,” added Vaks. The SORTEX range is customisable
manufacturing applications, and privately held Objet Ltd., a leading manufacturer of 3D printers for rapid prototyping, have unanimously approved a definitive merger agreement under which the companies would combine in an all-stock transaction with a combined equity value of approximately $1.4 billion, based upon the closing price of Stratasys’ common stock on April 13, 2012. The transaction will position the combined company as a leader within the high-growth 3D printing and direct digital manufacturing industry. www@stratasys.com www.objet.com
SUSTAINABILITY INITIATIVES IN COMPOSITES INDUSTRY THE SPE Automotive Composites Conference & Exhibition (ACCE) has teamed with Missouri University of Science & Technology (Rolla, Mo.) to develop an online survey to query members of industry,
The system operates at a high speed, removing unwanted colour, glued flakes and foreign material (including wood, aluminum and other metals) from clear and clear blue PET
The five-chute Sortex Z+ model can sort up to six tonnes of PET material an hour
with five optional modules. Its capacity can be adapted to meet the customers’ exact needs and the feed system is specifically tailored to the product, allowing for a wide range of chute options.” www.buhlersortex.com
academia, research groups, media, and government organizations globally about the importance of sustainability in the field of polymer composites. The survey, which is available at http://mst.qualtrics. com/SE/?SID=SV_cMbLor5uq3I3f3S , is open to anyone who wishes to participate. Results of the survey will be presented at this year’s SPE ACCE, from 11-13 September at the MSU Management Education Centre. www.speautomotive.com/comp.htm
LANXESS BUILDS NEW PLANT FOR HIGH-TECH PLASTICS IN BELGIUM SPECIALITY chemicals company LANXESS is investing €75 million in the construction of a new plant for high-tech plastics in Antwerp. The world-scale facility for polyamide plastics is designed for an annual capacity of 90 000 tons and scheduled to begin operation in the first quarter of 2014.
PBT pew IT IS a well-known fact that BASF provides support for its customers in the engineering of technical components. In the past, the company has also been involved in projects associated with the design of industrial and consumer goods. BASF has become even more involved with this topic in a new and comprehensive manner and offers designers even more intensive advice and practical support to help them develop their projects. One particularly impressive example is the MYTO chair, which was developed by the highly acclaimed German designer Konstantin Grcic in collaboration with the Italian furniture producer Plank and BASF. The chair is made entirely from the engineering plastic Ultradur® High Speed (polybutylene terephthalate – PBT) which has an extraordinary flowability. www.basf.com
OCTOBER / NOVEMBER 2012 101
SABIC’s new Noryl SA90 and SA9000 resins cut cost and extend performance capabilities of thermoset systems for printed circuit boards, adhesives and coatings
MATERIALS
New resins extend performance of thermoset systems for PCBs, adhesives & coatings SABIC’s Innovative Plastics business has launched a new breakthrough line of Noryl* SA90 and SA9000 resins that can be used as additives for epoxy and non-epoxy thermoset systems. These advanced new materials address expanding requirements and regulations for printed circuit boards (PCBs), including the call for enhanced sustainability, and exceptional overall cost control. Noryl SA90 and SA9000 resins can also be used by makers of pre-pregs and coppercoated laminates, electrical adhesives, composites and coatings – to significantly boost the performance and sustainability of their existing thermoset products without upgrading to more expensive materials. SABIC’s expert scientists modified the chemistry of SABIC’s renowned high molecular weight Noryl PPO polyphenylene ether resin to create low molecular weight, bi-functional oligomers that deliver an improved balance of low dielectric constant and loss factor, increased toughness and higher thermal reliability. The material also
provides substantially better moisture stability, more consistent dielectrics, and reduced loading of non-halogenated flame retardants (FR) vs. competitive products. Noryl SA90 resin, designed as an additive for epoxy and cyanate esterbased thermosets, provides lower dielectric constant and loss factor to enable better high-frequency performance (1-10 gigahertz (GHz)) in epoxy-based PCBs to help customers meet the demand for higher operating frequencies and nonhalogenated FR systems. Noryl SA90 resin is soluble (at loadings of up to 50%) in methyl ethyl ketone (MEK) at room temperature, thus avoiding the use of extreme solvents commonly needed for traditional polyphenylene ether (PPE) resins that can pose difficulties in safe handling in the electrical laminate market. Similarly, Noryl SA9000 resin provides lower dielectric constant and loss for improved high-frequency performance (up to 20 GHz) in non-epoxy based thermoset systems. It allows manufacturers to
provide non-halogenated FR in free radical cure (vinyl or triallylisocyanurate (TAIC)) PCBs. Both Noryl resins provide lower moisture uptake for more-stable dielectrics and higher glass transition (Tg) temperatures when appropriately formulated. For example, 40% Noryl SA90 resin in bisphenol A (BPA) epoxy can provide a Tg of 165 °C; Noryl SA90 resin used in other epoxy formulations can provide a Tg of 190 °C. Thirty percent loading of Noryl SA9000 resin in TAIC can provide a Tg of 250 °C, which is useful for solder float performance and may improve long-term reliability and thermal cycling behavior. They provide customers with a previously unmet market need due to their compatibility with the thermoset-based PCB laminating process and the excellent balance of high-end properties supplied by PPE.
www.sabic-ip.com
Reduced weight for robotics gearbox WHEN AndyMark, Inc. in the US, a company that invents and designs components for robotics and mobility applications, recently reviewed its catalog for components that could be improved, an aluminum gearbox kit captured its attention. Co-founder Andy Baker, a trained mechanical engineer, believed the housing could be made with a reinforced plastic, which would mean fewer parts for easier assembly, reduced weight, and increased durability. AndyMark is a one-stop shop for specialized robotic parts as well as everything else needed by robotic builders and hobbyists around the world. The growing company now supplies components for robotic competitions such as those spon102 OCTOBER / NOVEMBER 2012
sored by FIRST – a non-profit organization that helps students compete for scholarship funds by building their own robots. Baker had previous experience working with custom compounder RTP Company and sought their assistance again for a redesign of the aluminium gearbox. RTP Company engineers recommended using an RTP 200 Series very long fibre reinforced nylon 6/6 composite for the housing. The resulting gearbox redesign, called the CIMpleBox, has fewer parts, surer RTP-AndyMark-VLF-Gearbox
assembly, superior durability and, best of all, is 0.25kg lighter in weight. It is now the standard gearbox for all FIRST robot kits and more than 2,000 teams used it in 2011 competitions without a single failure. www.rtpcompany.com
COMING UP SPECIALTY PACKAGING FILMS THE specialty packaging films industry continues to grow and expand in complexity, with new materials, new barrier testing and quality control. AMI has scheduled the next conference on Multilayer Packaging Films 2012 from 16-18 October at the Maritim Hotel in Cologne, Germany, to highlight the latest trends. The flexible packaging market in Europe is valued at around 20 billion Euros by Andrew Reynolds, the Research Director at Applied Market Information. There is room for growth to replace rigid packaging and reduce weight. There is increasing globalization in this market as both food and packaging companies expand their geographical footprint. The focus for packaging is both on consumer appeal and product differentiation, and on improving sustainability in the supply chain. www.amiplastics.com
High-performance solutions at Plastex Cairo BATTENFELD-cincinnati featured its newest developments at Plastex, Cairo from 6-9 September, showcasing its new single and twin screw extruder series, as well as solutions for packaging and pelletizing applications and large diameter pipe extrusion up to 2 500 mm. So far, battenfeldcincinnati has successfully introduced three new extruder series to the market. The machines are easy to handle and robust, with energy-efficient AC motors for low maintenance. battenfeld-cincinnati is the market and technology leader in largediameter pipe extrusion and has successfully placed many lines in the field. Among them is a 2 500 mm line for producing fully walled PO pipes, equipped with a helix 2500 VSI pipe die (pictured here) which provides optimal wall thickness distribution with smooth inner surfaces.
www.battenfeld-cincinnati.com
DUBAI PLAST PRO FOCUSES ON PLASTICS BUSINESS IN MIDDLE EAST
WINDABA WINDABA 2012, South Africa’s premier wind energy event, takes place at the Cape Town Convention Centre from 22-24 October. This second edition of Windaba is jointly organised by SAWEA (South African Wind Energy Association) and its partner, GWEC (Global Energy Wind Council). First year running, the event attracted 400+ participants from 23 countries. WINDABA 2012 is set to be bigger and better, and is expected to bring together close to 600 professionals from around the world. www.windaba.co.za
GREEN BUILDING CONFERENCE IN CAPE TOWN THE Green Building Council’s Convention and Exhibition, South Africa’s leading green building event providing access to the latest, cutting edge, exciting information delivered by international and local leaders in the area, takes place in Cape Town from 23-25 October. The convention provides an inspirational platform for world-class education, knowledge sharing and decision-maker networking around sustainability and the built environment. The programme includes an education day, a two-day conference with keynote speeches and panel discussions as well as a comprehensive exhibition. www.gbcsa-convention.org.za
PROPAK West Africa 2012 THE inaugural PROPAK West Africa 2012, which ended in Lagos on 6 September, was an enormous success, providing exhibitors with the ideal opportunity to explore the possibility of expanding business opportunities in the West African region, while providing visitors from all over Africa with the opportunity to source from the widest range of suppliers. PROPAK West Africa was officially opened by the Minister for Trade & Investment in Nigeria, Chief Samuel Ortom, who emphasised that the Federal Government of Nigeria, as well as the Directors of Federal Ministry for Trade & Investment, have been fully supportive of PROPAK West Africa from the outset. “The objectives as set out by the
organisers of PROPAK West Africa are in direct alignment with the Federal Government’s desire to increase foreign investment into the Nigerian economy and to open up more business opportunities in Africa,” said Minister for Trade & Investment in Nigeria, Chief Samuel Ortom. PROPAK West Africa’s exhibitor list included leading companies from all over the globe, including: China, France, India, Italy, Nigeria, South Africa and Turkey. Leading company names included the likes of: Thermo Fisher Scientific, Heidelberg Nigeria Limited, Oakmond Nigeria Limited and Polyoak Packaging (Pty) Ltd. www.propakwestafrica.com
BOY XS has great showing at MICRONORA 2012 THE smallest BOY injection moulding machine, the BOX XS (clamping force 100 kN), was presented at the Micronora international micro technology fair in Besancon, France from 25-28 September. The 12mm plasticizing unit is ideal for the precise production of micro parts. Small injection volumes of up to 0.1 cm³ can be dosed precisely each time. Due to a small screw diameter and optimized screw geometry, the dwell time of the plastic in the plasticizing unit is reduced by 50% when compared with the 14mm plasticizing unit. With a footprint of only 0.8 m² (0.64 m² for the BOY XS V) and a clamping force of 100 kN, the BOY XS is ideally suited for micro injection moulding and sprueless single cavity moulding. www.dr-boy.de OCTOBER / NOVEMBER 2012 103
DIARY
THE 14th edition of Dubai Plast Pro, from 15-17 October at the Raffles Hotel in Dubai, UAE, will cover the important theme, ‘The Middle East Polymer Industry at a Turning Point: Challenges and Opportunities’. Building on the foundations laid by Maack Business Services (now a part of IHS Chemical), this event’s expanded three-day conference programme will feature more than 35 experts from across the global plastics industry focusing on the Middle East polymers/plastics business landscape and offering insight into solutions and opportunities. The plastics industry in the Middle East is poised for explosive growth as major raw material-producing countries seek to move downstream and widen their industrial base. IHS Chemical projects the region’s share of worldwide capacities of the five major thermoplastics PE, PP, PVC, PS, and PET to increase to 11% by 2016. www.ihs.com
DIARY
22nd FAKUMA promises top form WITH more than 1000 exhibitors, the Fakuma international trade fair from 16-20 October at the Friedrichshafen Exhibition Centre in Germany is once again in top form. The machinery and equipment sector for the plastics manufacturing and processing industry is once again the talk of
the town in 2012 with its impressive growth figures. Highlights for product presentations include stand-alone and system solutions which fulfill requirements for material and energy-saving production of plastic parts. This complex topic is the central thread
Maximum precision, brilliant results
Liquid silicone injection moulding
During Fakuma, Engel automotive will focus on energy efficiency and high finish quality requirements. In partnership with the client Gerhardi (based at Ibbenbüren in Germany), Engel will produce trim rings for BMW radiator grilles using an Engel duo 2550/500 pico. Galvanisation of plastic parts starkly reveals even the tiniest surface defects. Gerhardi has significantly reduced its number of rejects in recent years thanks to the high precision and process stability of ENGEL duo machines. Various machine features contribute towards this, for example, high-precision injection process control for the filling phase, holding pressure and the switchover to holding pressure, temperature control and water distribution (electronically monitored by Engel flomo) and a high degree of automation. An Engel viper 20 linear robot will remove the components from the mould at the trade fair.
www.engelglobal.com
Trim rings for BMW radiator grilles, produced at the ENGEL stand, will be chrome-plated after injection moulding
A COMPLETE integrated production unit to showcase a great new development this is how Negri Bossi aims to make its mark at Fakuma 2012. Negri Bossi will be showcasing the low-consumption, twoplaten ELEOS electric press for medical applications. One of the most compact in its category, this 80-ton press has a fully electric injection unit that carries out liquid silicone moulding for medical applications. Platen clamping/opening is also electrically
Long-life screws GROCHE Technik GmbH, based in Kalletal, Germany, has made a name for itself across Europe over more than 40 years as manufacturer of bespoke and standard high-quality/high-performance plasticizing screws and barrels for injection moulding and extrusion technologies. Today, the company’s products portfolio encompasses several hundred types of screws and designs. Diameters vary from 10mm to more than 200mm at lengths of up to 4,500mm. MD Armin Groche and his team at Fakuma will present the socalled ‘long-life screw’, together with some 75 other exhibits. With new screw coatings of a degree of hardness of up to 68-71 HRC (Hardness Rockwell), plasticizing extremely complex plastics does not pose any problems. These screws are used, for example, with polymers containing glass fibre or other highly aggressive materials in the metal or ceramics moulding sectors – in conjunction with high-wear and corrosion resistant bimetal cylinders
www.gt-plast.de
104 OCTOBER / NOVEMBER 2012
which runs through the entire process sequence for quality-conscious manufacturing of plastic parts, regardless of whether injection mouldings, extruded products or thermoformed work pieces are involved. www.fakuma-messe.de
powered. A hydraulic control unit with an inverter-equipped servomotor-driven system provides power for the core and ejector movements. The integrated production unit comes complete with an incorporated cartesian Sytrama robot and a clean room that will be used at the fair to produce feeding bottle teats (pictured here).
www.sacmi.com
Big interest in K 2013 Düsseldorf K 2013 is continuing where the thoroughly successful 2010 fair left off. The demand for stand space has risen sharply, and numerous exhibitors want to make a bigger impact at the fair. All 19 halls of Düsseldorf’s exhibition grounds will be fully occupied. Some 3,000 exhibiting companies will be participating in K 2013 from 16-23 October and presenting their offers from the fields of machinery and equipment for the plastics and rubber industry, raw materials, auxiliaries, and semi-finished products, technical parts and reinforced plastics to the global trade attendees. Suppliers from
Afriplast Expo 2013 THE inaugural Afriplast Expo 2013 will be held at Gallagher Convention Centre, Midrand, Gauteng from 14-16 May 2013 and form part of the S.A. Industry & Technology Fair. Pumps, Valves & Pipes, Petro.Tex Africa, Watertec Africa and Energex Africa will now be joined by six further titles (see Afriplast advert below for full details).
Germany, Italy, Austria, Switzerland and the USA will again be particularly strongly represented, while the number of Asian manufacturers from China, Taiwan and India has risen. Company exhibits will be supplemented by a special show entitled ‘Plastics move the world’. This is where aspects of the theme of mobility will be taken up – everything from lightweight design in the construction of vehicles, aircraft and ships, and electromobility to individual mobility and modern leisure behaviour. www.k-online.de
Commenting on the rationale of S.A. Industry & Technology Fair, described as an umbrella event for African industry, John Thomson MD of organisers Exhibition Management Services, said research began in 2009 on developments in the overseas exhibition market, particularly amongst trade fairs such as the Hanover Fair. “We found that as they added synergistic industry segments these shows were becoming more successful and more popular. That is when we first started co-locating some of our previously stand-alone events. We found that this co-location gave us criti-
cal mass that in turn attracted more exhibitors and more visitors – especially visitors from across our borders as the trip now became more viable for them,” Thomson added. EMS are organisers of, amongst others, the highly successful Southern African International trade exhibition SAITEX which this year attracted 916 exhibitors from 42 countries. This makes it SA’s largest and most international event. www.exhibitionsafrica.com OCTOBER / NOVEMBER 2012 105
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 GREEN ECONOMY CONFERENCE: 12 October Midrand Conference Centre: info@prodimensions.co.za AFRIMOLD 2012: 10-12 October Gallagher Conv Centre, Midrand: www.afrimold.co.za DUBAI PLAST PRO 2012: 15-17 October Raffles Hotel, Dubai, UAE: www.cvent.com MULTILAYER PACKAGING FILMS 2012: 16-18 October Maritim Hotel, Cologne, Germany: www.amiplastics.com/Events
WINDABA 2012: 22-24 October: CTICC, Cape Town: www.windaba.co.za
Light as a tool
GREEN BUILDING CONFERENCE: 23-25 October CTICC, Cape Town: www.gbcsa-convention.org.za
EuroMold presents first congress on photonic process chains
FAKUMA 2012: 16-20 October Friedrichshafen, Germany: www.fakuma-messe.de
POLYOLEFIN ADDITIVES 2012: 23-25 October Maritim Hotel, Cologne, Germany: www.amiplastics.com ITHEC 2012: 29-30 October Congress Centre, Bremen, Germany: service@ithec.de AFRICA OIL WEEK: 29 Oct-2 Nov: CTICC, Cape Town: www.petro21.com AGRICULTURAL FILM 2012: 6-8 November Madrid, Spain: www.amiplastics.com/Events AIRTEC: 6-8 November: Frankfurt, Germany: www.airtec.aero DRINK TECHNOLOGY INDIA: 6-8 November Mumbai, India: www.drinktechnology-india.com PACKTECH INDIA: 6-8 November: Mumbai, India: www.packtech-india.com
DIARY
2012 PETROCHEMICAL SEMINAR: 9 November Rio de Janeriro, Brazil: info@polyolefinsconsulting.com PETPOINT: 12-13 November Brau Beviale, Nürnberg, Germany: www.drinktec.com PETNOLOGY EUROPE 2012: 12-13 November Nuremberg, Germany: www.petnology.com 2012 SAEEC: 14-15 November Emperors Palace, Gauteng: convention@saee.org.za COMPAMED: 14-16 November: Düsseldorf, Germany: www.compamed.de EMBALLAGE 2012: 19-22 November: Paris, France: www.sacmi.com
EUROMOLD from 27-30 November in Frankfurt, Germany, is hosting the first Congress “Photonic Process Chains – The revolution in production”. This congress is organised in cooperation with the Federal Ministry of Education and Research, the Fraunhofer Institute for Laser Technology ILT and VDMA. At the congress, new trends and developments will be presented and discussed to fully unlock the potential of light as a tool for the next generation of production. The lectures deal with generative laser processes for the manufacturing industry, especially the automotive industry and the medical industry as well as specific methods for surface and tool structuring. Speakers will be high class representatives from leading companies and universities. The congress takes up the vast potential of photonic production. Generative or ablative laser procedures are already using digital data directly into tangible products. Without changing tools from piece to piece various shapes can be implemented flexibly – the mass production of customised products is getting possible. With the event, the full potential of photonics will be presented for the next generation of production. In addition, the Congress will contribute to design, construction, materials and production processes will be integrated into a clear concept that is focused on optical manufacturing processes and their capabilities. www.euromold.com
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 GPCA SUMMIT: 27-29 November: Jumeirah, Dubai, UAE: www.gpcaforum.net EUROMOLD 2012: 27-30 November: Frankfurt, Germany: www.euromold.com THIN WALL PACKAGING: 3-5 December Maritim Hotel, Cologne, Germany: www.amiplastics.com WATERPROOF MEMBRANES 2012: 11-13 December Hotel Nikko, Düsseldorf, Germany: www.amiplastics.com/Events 2013 ARABPLAST: 7-10 January Dubai Int’l Convention Centre, UAE: www.arabplast.info INTERPLASTICA 2013: 29 Jan-01 February Expocentre, Krasnaya Presnya, Russia: www.interplastica.de PIPELINE COATING 2013: 18-20 February Austria Trend Hotel Savoyen, Vienna: www.amiplastics.com/events DESIGN INDABA: 1-3 March Cape Town Int’l Convention Centre: www.designindaba.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 106 OCTOBER / NOVEMBER 2012
Cap-making technology SACMI of Italy exhibited a fully integrated turnkey solution for the manufacture of stretch-blow moulded containers, cap production, labelling and controlling and handling – at the China Brew & Beverage show in Beijing in September. A great deal of attention was focussed on the outstanding cap-making technology: CCM (continuous compression moulding) is currently the world’s most competitive solution for the production of mineral water caps, hot and aseptic filling. Designed by the SACMI Imola Closures Division, the top-of-the-range CCM 48SB was on show at the fair. Capable of producing up to 1600 caps per minute with just 48 cavities, the press produced three types of S29W caps in HDPE with diameters from 29mm and weighing just 1.25 g.
www.sacmi.com
Advertisers: OCT / NOV 2012 Afriplast Expo 105 Alpha Power Solutions 65 Associated Additives 33 BASF 79 Carst & Walker 49 ColorMatrix 13 Composite Plastics 73 DemaPlastech 63 DemaPlastech Rapid 83 DESMA 37 DH Polymers 37 Esteq 23 Extrupet 09 Hestico 71 Hi-Tech Elements 74 Hosaf 05 IDC 87 IOM 32 Jenowill 03 Karbochem 95 Masterbatch SA 89 MBT 35 MDS 67 Mercury Plastics 91 MGMW Trading 29 Miracle Mould 92, 93 MJH Machine Tools 54, 55 Mould Base SA 19 Mouldplas 77 Orion Engineered Carbons 01 Performance Colour Systems 21 Plasquip 81 Plastamid 53 PlastiChem IFC Plasticolors 11 Plastomark 97 POLYCO 15 Polysaf 51 Protea Polymers IBC Rawmac 101 Reichmans 99 Relloy OBC Relloy (Welding) 69 SABIC 17 SAPY Colours 47 SES 41 Standex Engraving 74 Sun Ace 27 Ultra Polymers 43 Univ of Pretoria 59
#,!33)&)%$ !$6%243 To place a classiďŹ ed advert please Fax: 086 519 6089 or Tel: 021 712 1408 or E-mail: saplastics@iafrica.com www.saplastics.co.za
GREENLAND OILS Michael Engels 072 125 4323 Tel: (011) 903-8084 Fax: (086) 665-4323 email: mengels1@ telkomsa.net PO Box 1220 Walkerville 1876
COMPOUNDING CAPACITY AVAILABLE We can compound mineral powders into PP or PE Please call Alon on 021 521 2400
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BATTENFELD BA 33000
ENGEL 800
Battenfeld BA 33000 Ton 2 K Machine with 3 Axis Part removal system, presently in production and operational.
Engel 800 Ton with 3 Axis part removal system in working order and presently in production.
FOR SALE
SPECS Size: 33000 KN Clamping Force | Output: 712 kg / Hr Screw size: 135 mm | Shot size: 7.6 kg â&#x20AC;˘ The Machine is planned to be stopped and ready for removal in CW 14 of 2013. â&#x20AC;˘ We will allow 4 weeks for removal, purchaser to remove the machine. â&#x20AC;˘ Rehau will assist with the use of a 50 Ton Crane overhead to remove heavy parts. 11 Major Parts of Max 45 Ton. Clamp Unit + Inj Unit = (237 000 + 26 000 kg) â&#x20AC;˘ ConďŹ rmation required and timing and Safety Plan to be agreed.
Contact: Alan Introna | E-mail: alan.introna@rehau.com Tel: +27 43 763 1471 | Cell: +27 8 36 35 31 30
FOR SALE
SPECS Size: 8800 KN Clamping Force Output: 190 Kg / Hr Screw Size: 80 mm Shot Size: 1.76 kg â&#x20AC;˘ The Machine is planned to be stopped and ready for removal in CW 14 of 2013. â&#x20AC;˘ We will allow 2 weeks for removal, purchaser to remove the machine. â&#x20AC;˘ Rehau will assist with the use of a 50 Ton Crane overhead to remove heavy parts. â&#x20AC;˘ ConďŹ rmation required and timing and Safety Plan to be agreed. â&#x20AC;˘ Can be removed in 2 Pieces of (40 000 + 20 000 kg)
Contact: Alan Introna | E-mail: alan.introna@rehau.com Tel: +27 43 763 1471 | Cell: +27 8 36 35 31 30
OCTOBER / NOVEMBER 2012
107
SPORTS
High-tech’ bikes with wheels manufactured using Umeco’s MTM49-3 woven carbon fibre reinforced epoxy prepregs
High-tech bikes Umeco’s competition grade prepregs for high performance bicycles GERMAN automotive, motorsport and competition cycling components manufacturer AX-lightness GmbH is using Umeco’s autoclave and press curable MTM®49-3 prepregs to produce structures for competition bicycles being used at national and international events. AX-lightness, the only developer and manufacturer of cycling structures that is also a key supplier into the Formula One sector, is the sponsor of Team Ghost Factory Racing, an all-women mountain bike team which competes at national and international level.
Three team members will be riding high-tech’ bikes with wheels manufactured using Umeco’s MTM49-3 woven carbon fibre reinforced epoxy prepregs. AX-lightness also uses a combination of Umeco’s unidirectional and fabric reinforced MTM49-3 prepregs to manufacture cycle components for an Australian triathlon athlete. AX-lightness chose to autoclave cure its structures to accommodate their intricate design features. Umeco’s MTM49-3 series prepregs are 80 to 160°C curing, toughened epoxy matrices developed specifically for the
manufacture of components requiring good impact resistance. These prepregs also exhibit excellent ambient and hot temperature mechanical performance after only moderate cure cycles, making them ideal for sports & leisure and motorsport applications. Umeco’s MTA240 adhesive film and MTF246 surface improvement film are fully compatible with MTM49-3.
Safe in the saddle
from a combination of regular polyester and Spandex. While providing a good fit and freedom of movement while cycling, these fabrics do not provide any protection in the event of a crash. DSM has developed cycling outfits with integrated protective parts using. A logical step was to explore the possibilities of using DSM’s UHMWPE fibre, branded as Dyneema®. Dyneema is 15 times stronger than steel while still being lightweight, flexible, cool to wear and extremely durable. Together with BioRacer, a Belgian producer of cycling outfits, and the Royal Dutch Cycling Association (KNWU), scientists from DSM succeeded in integrating Dyneema® in new generation cyclists’ bib shorts, with a clear benefit: in the event
of a crash, the Dyneema fibre offers much better protection because the fabric does not tear as rapidly as regular polyester. The new shorts feel soft on the skin thanks to the microfibre structure of Dyneema and are cool to the touch. The feedback received from cyclists of the Dutch national team is very positive. The shorts feel just as comfortable as the polyester versions, with the added benefit of being protected in the event of a crash. During the London 2012 Olympics, cyclists from the Dutch national team will use the new performance apparel with Dyneema during both the road race and the track cycling events.
Super-strong, protective against cuts, abrasion and tear CYCLING is one of the world’s most popular sports, practiced in many forms: road racing, track cycling and BMX, to name but a few. During a bicycle race, speeds of up to 110 km an hour can be reached during a typical downhill descent – and the danger of a serious crash is always present. Common crash injuries include serious cuts and bruises on arms and legs, causing discomfort, limiting a cyclist’s performance and possibly elimination from the race. Most common cycling outfits are made
www.umeco.com
www.dyneema.com
Together with BioRacer, a Belgian producer of cycling outfits, and the Royal Dutch Cycling Association (KNWU), scientists from DSM succeeded in integrating Dyneema® in new generation cyclists’ bib shorts, with a clear benefit: in the event of a crash, the Dyneema fibre offers much better protection because the fabric does not tear as rapidly as regular polyester Netherlands’ Marianne Vos reacts as she crosses the finish line ahead of Britain’s Elizabeth Armitstead to win the women’s cycling road race final at the London 2012 Olympics
108 OCTOBER / NOVEMBER 2012
â&#x20AC;&#x153;more than just a chemical supplierâ&#x20AC;?
BOOK EARLY BEFORE THE DECEMBER SHUTDOWN
dean@relloy.co.za