SA Plastics, Composites @ Rubber by SA POLYMER TECHNOLOGY

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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

www.saplastics.co.za

GAUTENG Lowrie Sharp t: (011) 793 4691 f: (011) 791 0544 c: 082 344 7870 e: lowrieplasticsmedia@absamail.co.za KZN Lynne Askew t: (031) 764 2494 f: (031) 764 0676 e: lynne@leafpublishing.co.za 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

Astrapak embarks on new strategy: searches for top 22 New CEO Moore outlines 5-year plan STRAPAK’S announcement in January that it is seeking 22 new senior managers was unusual, but also exciting. In years before Astrapak was at times the flavour of the month in the business press, but that happy relationship went out the window when the group’s financial results didn’t satisfy. The group’s new CEO, Robin Moore, and group MD Manley Diedloff seem to have been able to convince the Astra board that the best people to run plastics converting operations are individuals who have experience in the sector – or very definitely in the manufacturing business. According to the recruitment advertisements that appeared Five years from now, we’re in a number of leading Sunday aiming to be one of the newspapers, the new structure leading plastics packaging is focused on core technologies. Previously separate operating companies in Africa and a companies are being merged world-class performer by to form five key divisions, any benchmark. namely: Moulding (incorporating Cinqplast Denver, JJ Precision, Pak2000, Plastech, Plastop Bronkhorstspruit, Plastop KZN and Plastop Weener); PET (Cinqpet Denver and Hilfort); Thermoforming (Plastform and Thermopac); Flexible (Barrier, East Rand Plastics, Knilam, Packaging Consultants and Peninsula Packaging) and Development (Alex White, Consupaq, Geotex Plusnet and Marcom) “Astrapak’s current reality is the result of M&A activity over many years. While new businesses were acquired and added to the portfolio, there was no strategy to harness the collective as a means of delivering shareholder value,” said Moore. “Our restructuring plans create the necessary alignment and synergy, so that we’re able to optimise the group’s manufacturing capability, human resources and national footprint to deliver better customer service and grow market share,” he added. Among the group’s corporate office requirements are vacancies for a Best Practice & Continuous Improvement Executive, as well as a Sustainability Manager. “Five years from now, we’re aiming to be one of the leading plastics packaging companies in Africa and a world-class performer by any benchmark. Our research shows that we’re already in good markets and well positioned to compete. The next level is the challenge, which is why we’re changing the structure and appointing senior people who can help lead the way on crucial issues, like rapidly evolving technologies, as well as consumer trends in packaging, quality, safety and sustainability,” said Moore. Will they find the right people? The recruitment adverts are likely to attract a lot of interest and we may see top people from the other packaging ‘crossing the floor,’ but it’s clear that Astrapak is making a fresh start. If Moore, Diedloff and Co can mould them into a winning team, exciting times could lie ahead.

Association of Rotational Moulders of South Africa

of Southern Africa

Plastics Converters Association

PET Plastic Recycling

Plastics Federation

South Africa

of SA

Institute of Materials

METHING HAVE SO … IF YOU TO SAY de: if you e bright si Look at th isdom to w of e gem us at have som to te ri ease w impart, pl frica.com ia s@ tic saplas

Volume 11 No 1

REGLOPLAS

FEBRUARY â&#x20AC;&#x201C; MARCH 2013

Contents Find out more at www.saplastics.co.za

High-performance temperature control units â&#x20AC;Ś for large injection moulds, extruders, rollers, autoclaves and other processing equipment

INDUSTRY NEWS Plastinternational invests to save!

Type 90 Smart

CTP Flexibles installs 3 more Titan rewinders

Evron masters complex blow moulding challenges

SES â&#x20AC;&#x2DC;rebuildâ&#x20AC;&#x2122; process

Pilot project to recycle contaminated,

Temperature control units for water up to 90Â°C

â&#x20AC;˘ Controller RT61 PID â&#x20AC;˘ Heating capacity 9 kW â&#x20AC;˘ Cooling capacity 24-90 kW â&#x20AC;˘ Pump capacity 60 litres/min, 3.8 bar

coloured, black polystyrene

ASSOCIATION NEWS New PVCMedAlliance to promote medical use of vinyl

Plasticsâ&#x201D;&#x201A;SA conference promises lively debates

Type 150 Smart

Temperature control units for oil up to 150Â°C

PROPAK Pro-Plas Africa will be main 2013 even for region

FEATURE Turkish polymer industry resilient and growing

DESIGN Students point the way to great industrial design

WORLD Engel hands 1500th machine to Lego

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

SPORTS Marathon on ice

at 400V 6 kW â&#x20AC;˘ Cooling capacity 28kW @ 140Â°C â&#x20AC;˘ Pump capacity 60 litres/min, 3.8 bar

DIARY Events coming up in 2013

â&#x20AC;˘ Controller RT61 PID â&#x20AC;˘ Outlet temperature max 150Â°C â&#x20AC;˘ Heating capacity

ON THE COVER The high elongation possible with AmodelÂŽ PPA (polyphthalamide) from Solvay Specialty Polymers has enabled Nissan Motor Company in the USA to eliminate the parting line commonly occurring in the injection moulding of a complex water pump. This feature allows moulders to eject the parts from the mould without producing a parting line in the barbed area, unlike conventional injection moulding. These materials are supplied locally by Solvay Polymers & Chemicals SA of Pretoria. See page 56 for more information.

www.mpc-inc.com www.solvayspecialtypolymers.com

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

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

THIS ISSUE

Turkish times – The publisher was recently caught perusing a local newspaper in the town of Fetiya on Turkey’s southern coast, on the Med. Did he understand even a word? Not really necessary, said Wells, the Turkish papers tend to be packed full of pictures of busy people. In fact, that is the culture of the Turks: everyone’s involved in business, which has created the situation where Turkey has one of the healthiest economies in the Europe-Asia region

Good signs that industry

can regain momentum AST YEAR was tough for most of us … but it could have been even tougher: it was a big relief that the industry largely escaped serious labour activity during the period.

COMMENT

Let’s not suffer any illusions: a toyi-toying mob at your factory gates can put you off work on a long-term basis. Several businesses were hit by strike action in 2011 and it’s a credit to the industry that most employers (and employees alike) appear to have learned from the experience. Sustained labour action can be highly detrimental and result in the loss of customers and even market share for the industry overall, which has become a reality in several other sectors. We can’t afford to go down that route. It’s no surprise that the challenging economic conditions over the last few years have ratcheted up pressure in the manufacturing sector, leading in many cases to increasingly different expectations on the employer and employee sides. A statement that is often aired at wage or labour related discussions, ‘We can’t afford to pay the ﬂoor sweeper the minimum wage’, may be true, but you can’t afford to employ someone to sweep only. Our observation is that there is no such thing as a ﬂoor sweeper in this industry. One of the top medium-sized blow moulding business owners recently mentioned that machine minders at his company are, on appointment, given a broom and informed that it is their responsibility to keep the area around their machines clean and tidy. Okay, the fact that staff at this company keep the production area tidy is not the only reason why it’s a successful operation. Most companies in the plastics, composites and rubber sectors are operating high-tech and expensive equipment and it’s virtually a privilege for production staff to have the opportunity to work with such equipment

FEBRUARY / MARCH 2013

and create careers for themselves. Even at companies where fewer or dated machines are used, the same applies – some business owners prefer to run at a slower pace and if that’s what works for you, that’s what matters. The magic recipe for employers is to achieve a state where staff are MORE PRODUCTIVE. It’s impressive that many of the companies in our industry around the country are chartering courses through this morass and achievMagic recipe ing the goal. Most of our readers for employers are either company owners or is to achieve involved in senior management, a state where so congratulations to you all – staff are MORE we need to make it work and for the industry to resume the PRODUCTIVE growth path which characterized it for so many years before. This edition of our publication contains articles about achievements by many in the industry, both locally and globally, so please read on. Propak Africa: main building block for our industry PROPAK Africa at the Nasrec Expo Centre in Johannesburg from 12-15 March is the main event and meeting place for the industry in southern Africa. Many of SA’s top converting businesses will be showing their packaging solutions and systems at the main show and approximately 40 of the suppliers to the industry (including equipment, materials and services suppliers) will be exhibiting at the parallel Pro-Plas Africa exhibition. The last edition of Propak Africa was held in 2009, and a lot has happened in the four years since. The event is going to be fun, interesting and worth attending. See you there!

uppe marketing A08303

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BASF South Africa (Pty) Ltd (Plastic Additives) Charis Lewis Tel: +27 11 203 2596 Cell: +27 71 670 2407 Fax: +27 11 203 2602 E-mail: charis.lewis@basf.com

JUST BRIEFLY Nampak achieves good results in Africa NAMPAK’S results for the year ended 30 September 2012 reveal that trading profit from the rest of Africa increased by 159% following good contributions from Angola and Zambia. Group trading profit increased by 16% to almost R1.8-billion and the trading margin by 10.2%. Group revenue increased by 12% to R17.6 billion, whilst revenue from the rest of Africa increased by 55% to over R2billion with a full year’s contribution from the beverage can operation in Angola. CEO Andrew Marshall said a number of exciting opportunities had been identified that will contribute to Nampak’s growing presence on the African continent. He said the company was on track to generate at least 35% of its total revenue from the rest of Africa by 2015. The plastic milk bottle business in the United Kingdom had an excellent year despite very challenging market conditions.

Big Unilever plant in Boksburg UNILEVER group is building a major plant for the production of home care products in Boksburg in an expansion programme valued at an estimated R1-billion. The programme involves the construction of a R800-million new plant as well as the upgrading of its existing plant. Work on the site started recently and it’s expected to be in production by 2014. Unilever SA chairman Marijn van Tiggelen said the factory was one of the group’s largest investments globally and was aimed at supporting its commitment to customers in southern Africa. www.unilever.co.za

East Rand Plastics recovers after blaze THE fire at East Rand Plastics in Brakpan in January severely damaged the business’s printing and recycling operations. The main extrusion and bagmaking plants were fortunately not affected. It is reported that the fire started in the print and solvent storage area, but investigations into the exact cause are underway. East Rand Plastics has been quick to recover, however, managing to continue to supply many of its customers through the other film manufacturing businesses in the Astrapak group, including Packaging Consultants in Durban and Peninsula Packaging in Cape Town. 6 FEBRUARY / MARCH 2013

Plastinternational

invests to save! Energy saving solutions from Ferromatik also offer better quality moulding PLASTINTERNATIONAL, one of the most accomplished and longest established custom injection moulding companies in Gauteng, recently took a leap into a new era – energy saving production. Operating out of Meadowdale, Johannesburg, and running machines from 20 ton up to 450 ton clamp force, Plastinternational manufactures products from as small as 0.0005kg up to approximately 1.9kg shot weight. Gianni and his son Luca, together with their 35-strong team, have developed expertise in several areas, speciﬁcally the production of the company’s proprietary range of SABS approved ezeeFLOW™ plastic ball valves, pipe ﬁttings and various components for water meter management

systems. With its customers being their number one focus, the Ambrosi’s began investigating leading edge alternatives to control ever increasing input costs in their plant. Over the last few years a major contributing factor has been the signiﬁcant increases in electricity supply. This together with labour costs has driven up component prices in the local market and has opened the doors to ‘cheaper’ imports, severely affecting the local manufacturing segment. In

See that donkey at night! Innovative project using reflective ear tags reduces hazard of donkeys on roads at night MAUN Animal Welfare Society in Botswana has launched a pilot project to attach reflective ear tags to donkeys in the district. Donkeys roaming on the roads at night create a The are reflecti dangerous situation man ve t ags uf for both beast and Info actured p by l ast P o o rt El vehicle. izab f eth Funded by SPANA, a UK-international working animal charity, the pilot project will issue tags

to 500 donkeys to reduce collisions. Donkeys are particularly vulnerable because their eyes do not reflect car headlights. The heavy-duty ear tag used for the project renders both sides of the ear reflective to oncoming car headlights, ensuring the donkey should be visible whether it is facing towards, away from or side-on to traffic. “In this region the donkey to human ratio is a staggering 1:2,” said Ally Lamb, chairlady of Maun

Amcor invests $20m in new Florida, USA plant AMCOR Rigid Plastics, one of the world’s leading producers of PET and other packaging containers, has invested approximately $20-milliion in the expansion of its plant in Orlando, Florida, where it is centralizing preform production and warehousing while delivering key sustainability advantages, including improved logistics and shipping efficiencies. Amcor recently relocated from an existing 15,000m² plant to the new leased 46,000m² site in the Airport Industrial Park of Orlando, just a few kilometres from the former location. The multi-million dollar investment funded major construction work to convert an unfinished shell structure into the new highly functional space for the production of hot fill and cold fill PET bottles for beverages such as sports drinks and orange juice, along with HDPE pharmaceutical as well as other LDPE containers. Amcor recently unveiled the new facility during a grand opening celebration, attended by state and local officials. The company has operated as a bottle manufacturer in Orlando since 1979. Amcor will manufacture a majority of its preforms inhouse at Orlando, thus eliminating the previous cost associated with shipping in preforms. The new expanded facility will eliminate the need for three offsite warehousing sites. In terms of future expansion, Amcor also has room to increase manufacturing. The current expansion is expected to result in a net increase of 29 new jobs with employment reaching approximately 150 workers by next year.

INDUSTRY NEWS Luca and Gianni Ambrosi, Plastinternational’s fatherand-son team, with one of the new 150-ton servocontrolled ‘Omega’ Ferromatik machines installed at the Johannesburg company; a number of the Ferromatik servo machines, up to 450t, have also been installed

order to best serve its customers as well as delivering to market price competitive products, they decided to implement energy saving technology which is now offered on Ferromatik Milacron injection moulding machines. The company recently installed ﬁve brand new machines in what is the start of a major investment programme undertaken by PlastInternational. Represented locally by SES, the Ferromatik machines are built in India, using

technology and components from their German principles but at lower cost – due to the lower land and labour prices in the sub-continent. The use of servo based motors on the Ferromatik machines has resulted in improved quality of product as well as great savings for their clients. Luca Ambrosi said the improved consistent quality, efﬁciency and energy savings realised thus far have been considerable

Animal Welfare Society (MAWS). “Our objective is to prevent these accidents, saving the lives of the occupants of the vehicles as well as the donkeys, simply by making them more visible at night. With an additional 24 500 donkeys in Maun that still require tagging, MAWS is hoping to continue the project over the coming months. Stephen Els of Infoplast, the South African manufacturer of the tags, said: “Botswana and Namibia are the only subSaharan countries to have successfully implemented these programmes. There has been extensive interest in RSA for reﬂective tags, but the projects always ground to a halt when it came to implementation. “A tagging programme for stray donkeys is no small feat. I really take my hat off to the individuals driving these organisations

- they clearly have a strong will and great ability,” said Els.

and well worth the major investment. • PLASTINTERNATIONAL TOGETHER WITH ITS SISTER COMPANY, ATLAS PLASTICS, IS ABLE TO OFFER EXTRUSION, ROTATIONAL MOULDING AND COMPLETE ASSEMBLY LINES.

www.plastinternational.com

• INFOTAG, PHONE 013 254 0482 • ORIGINAL ARTICLE SUPPLIED BY ‘ZAMBEZI TRAVELLER,’ A QUARTERLY NEWSPAPER THAT COVERS THE TOURING AND WILDLIFE SECTORS IN THE ZAMBEZI RIVER AREA.

www.zambezitraveller.com www.maunanimalwelfare.com Donkeys’ eyes do not reflect light at night, which makes them vulnerable along roads during the night. The new reflective tags being fitted to donkeys in Maun, the ‘entrance’ to the Okavango delta in Botswana, is intended to reduce this danger for both the animals and motorists PHOTO: MAWS

• Amcor is headquartered in Melbourne and is listed on the Australian Securities Exchange.

www.amcor.com

FEBRUARY / MARCH 2013 7

Scenes such as this, of highly intensiﬁed mobility situations, are a daily reality for millions of people in urban environments around the world. Lanxess is proposing plastics and rubber materials solutions, to reduce carbon emissions and make the experience healthier for commuters

Mobility will be big focus of 21 century st

Lanxess group hosts pow-wow in PE

INDUSTRY NEWS

MOBILITY is the name of the game, certainly for the 21st Century. Lanxess group of Germany has hit the nail on the head with its view that the mobility market – whether by automobile, other means of land transport, air or sea – is going to grow further, from its already massive base, during this century. In the case of Lanxess, a global supplier of specialised rubbers and high-tech plastics, the focus is fully on the automotive sector, where it is one of the top material suppliers. Lanxess hosted a ‘Mobility Day’, aimed at component suppliers to the automotive OEMs in Port Elizabeth in November, an event attended by many of SA’s top plastic and rubber auto part manufacturers. The SA Mobility Day followed on similar successful events held earlier in 2012 in

1. High-tech plastics – Hartwig Meier and Martin Wanders of Lanxess Germany gave presentations at the plastics ‘breakout’ session

Shanghai (China), Charlotte (US) and Prague (Czech Republic), all notable as leading automobile production centres. The Port Elizabeth event possibly shared more in common with the Czech event, with Prague also being mainly an export-based manufacturing centre. Lanxess supplies butyl rubbers butadiene rubbers rubber chemicals Durethan® engineering plastics based on polyamide 6 and 66 Pocan® engineering plastics based on polybutylene terephthalate Lanxess showcased its latest generations of high-performance rubber and additives at the one-day conference. These help the tyre industry to produce ‘green’ tyres, which are particularly fuel-efﬁcient. The group also

2. Daniel Taylor and Richard Dobson, who were both previously involved in material supply in South Africa, gave presentations in the rubber session. Daniel was originally with PlastiChem and then joined DSM Elastomers in Holland, which business was subsequently bought by Lanxess group. He now works for Lanxess Elastomers. Originally with Bayer in SA, Richard now works for Lanxess in Switzerland, specializing in Butyl rubber business

demonstrated its knowhow in the field of hightech plastics. Thanks to their properties, these premium products are able to replace heavy metal parts in cars and lower consumption and CO2 emissions without compromising on safety. “In the future, mobility around the world will need to become more sustainable and consume fewer resources than it does today. With its high-performance rubbers and high-tech plastics Lanxess is making an important contribution to such green mobility,” said Karl-Rudolf Gassen, MD of Lanxess in South Africa. “As South Africa is the doorway to Africa’s automotive sector, it is fitting to introduce Lanxess’ green mobility enabling products in a location like Port Elizabeth, a hub for the automotive industry.” The automotive sector is showing promising growth in South Africa. The output of 2011 of 540,000 units was a 15% increase on the 2010 figure. Overall new car and commercial sales for

3. DTI presentation – Dean Delaporte of PlastiChem with Renai Moothilal of the Depart of Trade and Industry, who outlined the DTI’s incentive packages and strategies to boost industry

4. Keynote speakers – Guest speakers at the event included Simon Gear, well-known in his previous role as TV weatherman but who has switched careers and become an climatologist/ environmental strategist as well

All new vehicle tyres in the European Union have had to bear the EU tyre label since November 2012. The conspicuous markings, which consumers already know in a similar form from refrigerators and washing machines, rate the rolling resistance (i.e. consumption) and wet grip (safety) of tyres. They also show the level of rolling noise. High-performance rubber from Lanxess already enables the tyre industry to develop models that achieve good values in these areas (above) Improved safety in wet conditions is one result of high-quality ‘green tyres,’ speciﬁcally the ability to bring vehicles to a standstill more quickly; Lanxess produces the high-performance rubber fundamental to the production of these tyres (left)

October last year reﬂected another encouraging performance compared to the corresponding month of 2011 year. Aggregate industry domestic sales for October 2012 were 57 845, a 10.5% increase (5 519 units more than in October 2011). Export sales for October 2012 at 24 904 vehicles were however down by 3.3%. • PLASTICHEM IS THE AGENT FOR LANXESS IN SOUTH AFRICA

About Lanxess Lanxess is a leading specialty chemicals company with sales of EUR 8.8 billion in 2011 and currently around 17,100 employees in 31 countries. It currently operates 49 production sites worldwide. The core business of Lanxess is the development, manufacturing and marketing of plastics, rubber, intermediates and specialty chemicals. Lanxess is a member of the leading sustainable indices Dow Jones Sustainability Index (DJSI) World and FTSE4Good.

as, coincidentally, an amusing and entertaining public speaker; and Trevor Stroud of the Nelson Mandela Metropolitan University, whose presentation outlined research being conducted into enhancing vehicle dynamics at NMMU

Transport, whether by motor vehicle, plane or boat, among others – is set to be a main priority of the 21st century, and is most likely to gather further momentum

5. Stuart Gibson of Thread Management of Mauritius with Daniel Taylor and Marcel Niemeck of Lanxess

6. The never-ending quest for perfection led Thys du Plessis to bring along an auto component that was warping for inspection by the German fundis

7. Helmut Oellermann (in red tie) of PlastiChem, which supplies the Lanxess rubbers and plastic specialties with Gareth Comely and Niko White of Principle Plastics of PE and Arno Taljaard of Lumotech of Uitenhage

3 4

1. Lanxess produces the high-performance rubbers fundamental to the production of low-rolling-resistance tyres: Lanxess is extending its range of highly elastic neodymium-polybutadiene (Nd-BR) rubbers with a grade of particularly high viscosity – Buna CB 21 – which is highly appropriate to cut the rolling resistance of car tyres

2. High-tech plastics help to reduce weight in automotive components and hence CO2 emissions: Pocan TP 525-001 enables components to be produced without timeconsuming post-moulding treatment and is about 20% lighter. The blend’s excellent coatability is a further advantage as some Eurocargo bumper models are painted

3. Lanxess’ focus is on developing new applications for high-tech plastics together with its partners in the automotive industry 4. Hot seat – The Mobility experience is undoubtedly enhanced by a comfortable seat

INDUSTRY NEWS

Clear trend toward new materials era for ‘green tyres’ LEADING FIGURES in the tyre industry globally see a clear trend toward low-rolling-resistance tyres. What’s more, this will hardly be possible without improved highperformance solution styrene-butadiene rubber grades (SSBR) as well as Nd-PBR (Neodymium-based Performance Butadiene Rubber) and so the sector is increasingly looking to work together with highly specialized synthetic rubber manufacturers. These are two of the most important results of an extensive study about the SSBR market performed on behalf of Lanxess by consulting company Stratley Portfolio Performance Incorporated. One question that remained open until now was to what extent the increased attention to detail on the part of the customer would impact the demand for SSBR – which is, alongside Nd-PBR, the second high-performance rubber that experts consider to be essential for the development of economical, safe, long-lasting tyres. In total, the Stratley experts commissioned by Lanxess have assessed the opinions of 32 tyre manufacturers with combined sales of around US$ 130 billion (corresponding to around 84% of the global 10 FEBRUARY / MARCH 2013

tyre market). These included all the top 20 suppliers in the industry. Results give consistent picture Their findings give a surprisingly consistent picture of the sector as a whole: 85% of all tyre companies questioned expect the new EU regulation to significantly impact their daily business, with most seeing this as an opportunity rather than a burden. In high-performance tyres, SSBR – particularly in combination with silica fillers – is expressly considered by many to be an absolute must. The authors of the study believe that in a few years SSBR will have significantly overtaken conventional emulsion-styrene-butadiene rubber (ESBR) – in five years’ time twice as much SSBR will be used in car tyres as ESBR. The global tyre industry experts are extremely interested in how the SSBR grades currently available will continue to develop. The supply of ever better green tyres will be largely dependent on the provision of increasingly refined SSBR grades. As a pioneer in synthetic rubber, Lanxess has expertise in SSBR chemistry and production technology that is unique www.lanxess.com

worldwide. “Our most recent investments in debottlenecking our SSBR and NdPBR-production plants in Europe, Brazil and the United States and increasing their flexibility – along with the building of our 140 kt Nd-PBR facility in Singapore – show that we want to maintain our reputation as a reliable supplier of high-performance special-purpose rubber for the tyre industry,” Grub says. Tyre labelling key driver November 2012 saw the launch of mandatory tyre labelling in the EU. Tyres are graded from A to G according to their fuel efficiency and wet grip. Rolling noise is also measured. The new legislation provides more transparency for consumers by highlighting the added value of ‘green’ tyres. Japan and South Korea were the first countries in the world to introduce a label system. After a voluntary tyre label was introduced in Japan in January 2010, South Korea launched its voluntary labelling in November 2011 and a mandatory label in December 2012. Other countries like Brazil, the USA and China are expected to follow in the coming years.

www.plastichem.co.za

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71699 SA Plastics 279x210.indd 1

2012/12/10 11:31 AM

INDUSTRY NEWS Redevelopment of the CTP Flexibles Cape Town site has resulted in a 5000m2 slitting hall where seven of the ten slitter rewinders are Titan machines Some of the high quality ﬂexible packaging materials produced by CTP Flexibles

CTP Flexibles installs 3 more Titan rewinders IN recent years, CTP Flexibles, the Cape Town based converter of flexible packaging materials has achieved dramatic expansion of its business. In 2010, the company installed a new 8 colour Fischer & Krecke FP16-S flexo printing press and in order to cope with the increased printing capacity it also installed two Titan ER610 compact slitter rewinders – one 1650mm and one 1350mm wide machine. Further increases in production to serve its expanding ‘blue chip’ customer base led to the addition of three more 1350mm wide Titan ER610’s during the first few months of 2012. This brought the total number of Titan ER610 slitter rewinders at CTP Flexibles to five machines – and seven Titan slitters in total, if two older machines are included. “We are enjoying record sales and now operating 24/7,” explained Gary Seale, MD. “With the five new Titan ER610 slitters we now have ample capacity to cope with both current demand and also future expansion of our business. Having installed the two Titan slitters during 2010, we had every

confidence to invest again with Titan,” he confirmed. “For our production requirements, these slitters really are the perfect solution.” CTP Flexibles manufactures specialised plastic extrusion and flexible packaging materials mainly for the food, beverage and confectionery industries. The company is part of the CTP/Caxton group and has been producing high quality flexible packaging since 1971. “We produce everything here,” Seale added. “We extrude high-density, lowdensity and linear low-density polyethylene films and produce cast polypropylene films. We also manufacture a comprehensive range of sophisticated products from laminations, multi-layer films and shrink films to bags, pouches and shrink sleeves.” The Titan ER610 compact slitter rewinder has been a great success with sales of more than 100 machines worldwide. It has a maximum rewind diameter of 610 mm, a 10” touch screen control system and an integral edge-trim extraction system.

The pneumatically controlled braking system provides accurate web tension control and a digital edge-guide system controls lateral movement of the unwind reel to +/- 50 mm. The minimum slit width can be as narrow as 25mm at speeds up to 450 m/min. Slitting systems available include shear knives, rotary razor (burst) or razor slitting in air or groove. Optional features include an anti-static control system, laser (line) core positioning and an option for shaftless unwind roll pick-up from the floor, which is included on all five Titan ER610 slitters commissioned at CTP flexibles. • THE TITAN EQUIPMENT IS SUPPLIED LOCALLY BY BESWICK MACHINERY OF JOHANNESBURG. ww.beswick.co.za www.ctpflexibles.co.za www.atlasconverting.com

Mattman indexing carousel tests up to 10 000 bottles/hr Mattman of Johannesburg, which specialises in machine controls and rebuilds, has recently begun to build its own range of equipment, a signiﬁcant achievement for a South African company. Its most recent design is a 5-head indexing carousel for a dairy bottle manufacture that is able to test in excess of 10 000 one-litre bottles an hour. The machine uses the Siemens Simotion servo controller with an index speed of less than 0.3 sec. The advantage of this is improved energy saving as there’s no vacuum conveyer running all the time. The servo control has an integrated regenerative system, so all breaking energy is fed back into the main power ‘grid’. The servo motor is around 1.5kW, as opposed to a vacuum conveyer which would use around 3kW – which is an important advantage, bearing in mind that the servo motor is only used on each index and the braking forces are fed back to the grid. The latest design offering is a combined QC station, where the bottles are tested for leaks. Mattman can also offer weighing as well as vision inspection and packing using 3-axis robots, with a built-in leak tester and using the Simotion servo controls. The bottles are tested and if passed, then packed into boxes by the 3-axis robots. The equipment is built in-house by Charles Glieman and his team at Mattman in Midrand.

www.mattman.co.za 12 FEBRUARY / MARCH 2013

INDUSTRY NEWS

Evron masters complex blowmoulding Expertise in post-moulding finishing and assembly work required EVRON of Port Elizabeth, one of South Africa’s top manufacturers of technical and complex blow moulded parts, has further developed its prowess in this demanding area. That’s been necessary, since the increasingly compact design trend being pursued by automotive designers is necessitating the production of complex ducting components for the conveyance of air and fluids in the engine compartment. Besides weight savings, the main advantage is that complex shapes can be achieved more readily in plastic than in metal. But it’s been a difficult challenge for Evron: compared to packaging containers, which generally have uniform wall shapes, mould design costs for complex shaped structures tend to be significantly higher. The ducting or container parts also frequently require post-moulding work such as trimming, cutting, welding and assembly. Although expertise at complex blow moulding is the name of the game, there’s a limit to the process too: in several cases the final component is produced from a number of mouldings which are then joined. In fact, for most of the automotive ducting or container jobs, a ‘work cell’ needs to be created. Evron’s expertise lies in this area. Besides the actual blowing process, success in this area has also required the ability to effectively coordinate post moulding work, such as jig construction for cutting, welding and assembly. The company was established way back in 1966 by brothers Colin and Ronnie Ward and gradually developed the skills to handle complex blow moulding jobs. With the shift by automotive manufacturers towards using more plastic components in ‘under the hood’ applications over the past two decades, increasing numbers of ducting parts are

now being moulded in plastic. And Evron has been ready for the challenge. Many of the jobs require close cooperation with the vehicle designers, and many of the jobs require significant modification after on-road testing. The use of specialised materials (including combinations such as polyamide and elastomer blends) to achieve high heat resistance as well as flexibility are further challenges for the Evron team, but that’s the name of the game for this focused Port Elizabeth business. EVRON: PHONE 041 484 6326 www.evronplastics.co.za It’s a complex matter – Colin Ward of Evron with an automotive water tank and inlet moulding (which are produced separately) as well as (right) an air inlet duct, including a bellows section which allows the part to swivel. Port Elizabeth-based Evron, in operation since 1966, specialises in the production of complex blow moulded items such as these

Evron’s operation involves quite a lot of ‘tweaking’: parts are often trialed on vehicles during which vibration, noise generation and other factors are monitored. The company’s ability to make adjustments to designs has become a market advantage for it, and also enabled the automotive OEMs to produce quieter and more efﬁcient solutions

GF sells Haitian to Cinqplast 280t machine for Cinqplast – Denver-based Cinqplast/Plastop recently installed a 280-ton Haitian injection moulding machine from GF Plastic Machinery Services. Herman Potgieter, injection moulding production manager at Cinq (centre) was on hand when the energy-saving machine was commissioned. The company operates seven other Haitian machines, installed

14 FEBRUARY / MARCH 2013

since 2004, and all are operating at full capacity, said Herman. GF was represented at the event by George Ferreira jnr and George Ferreira snr. GF is no longer the sole agent for Haitian, one of the most popular of the Chinese injection machines in southern Africa, since it has opened its own ofﬁce in SA, but GF is continuing to supply the machines on demand.

JUST BRIEFLY Ferro buys NCS Resins FERRO Industrial Products has bought NCS Resins, one of South Africa’s top suppliers of unsaturated polyester resins manufacturers. NCS (founded in the early 1900s as Natal Chemical Syndicate) also supplies a complete range of composite resins, gelcoats and reinforcing fabrics and ﬁbres. Owned at different stages by Sentrachem group (from 1988) and then by global group Dow (from 1997), NCS went back to private ownership in 2001 when an MBO and simultaneous merger with Vereguard group took place, with Brait SA as the equity partner. Investec took over as the principal shareholder in 2010, and sold out to Ferro last year. Ferro is a main supplier to the ceramics, powder coating and plastics (masterbatch) sectors, among others. NCS manufactures under a licence agreement with Reichhold group – which is, like Ferro, a leading supplier to the coatings industry.

Trio moves into Ogatin premises TRIOPLASTICS has moved into the premises vacated by Ogatin in Jacobs Street, Chamdor. A supplier of PVC film and sheet (rigid, flexible) for thermoforming and folding box grade, as well as PET and PP sheet, Trio previously operated from Stormill. One of the attractions of the Krugersdorp site is that it has significant installed electricity capacity, which Trio did not have access to previously. Trio sales manager Mike Wright was, ironically, at Ogatin before. Ogatin has moved from Krugersdorp to Industria, closer to the Jozi CBD. Part of the First Technology group, Ogatin is a profile extrusion operation which manufacture conduit as well as conduit fittings, mainly for the electrical business. www.trioplastics.co.za

Tyre recycling plan approved … or has it? THE application by the Retail Motor Industry Organisation (RMI) to prevent the REDISA (Recycling and Economic Development Initiative of South Africa) waste tyre plan from being implemented was rejected in the North Gauteng High Court on 30 January. This means REDISA can now proceed with its plans. The legal dispute was just the latest in a series of objections to the REDISA plan by RMI which saw numerous court appeals during 2012. Part of the disagreement between the parties is due to the waste tyre reduction targets set by REDISA, which for some reason were omitted from the version of the plan published for public comment. 16 FEBRUARY / MARCH 2013

INDUSTRY NEWS

SES ‘rebuild’ process results in virtually new machines International automotive standards technology applied GETTING the most out of any machine is obviously a sensible strategy for a manufacturing business and in some cases that involves rebuilding older machines using the rugged frames and core components. One company that specialises in this area is SES of Wadeville, Johannesburg, which has developed skills for the complete rebuilding of injection moulding machines. This was a natural extension of SES’s machine support activities: SES has taken the process to the next level and is producing a range of rebuilt machines – the ‘SKR’

line – which are suited to conditions in southern Africa. The rebuild process has gathered momentum over the past two years with the appointment of Chris Kemp, who has transferred skills gained over the past two decades in the automotive sector to the injection moulding technology area. If anything, moving into the production machinery sector has provided a new lease on life for Chris. Chris started his career in 1991 with Mercedes Benz, working as a motor vehicle technician. After completing his national N6 qualiﬁcation, he qualiﬁed and worked at Mercedes Benz for seven years before joining Porsche in May 1998, where he performed duties like normal servicing, engine and transmission and even vehicle

Tooling @ Work partners bring out the best of both TOOLING @ Work, the East Rand mould and die making business which specialises in complex moulds for components such as gears, has found that the different experience and skills of founding partners Steve Langford and Nelson Adriao has enabled them to achieve even better solutions than they were able to when they formerly traded individually. Langford and Adriao effectively combine their skills and experience as qualiﬁed tool and die makers, with proﬁciency in the use of computer technology and on-going R+D in the development of tooling for compo-

nents and end products used in a broad spectrum of industries. Key clients include Rumig, AEL, Robert Bosch SA, Centurion Systems and Prevail Engineering. Stephen qualiﬁed in the UK and has worked in South Africa since 1983, initially as a contractor to various toolrooms; he subsequently established his own business in Johannesburg. Nelson attained his national diploma in tool and die making in 1996, having served a four-year apprenticeship. They ﬁrst worked together in 2000, when they both joined Tooling Production Services, a toolroom and production facility

Tooling @ Work – Stephen Langford (left) and Nelson Adriao (right) have found their varied experience and skills has been complementary and, when pooled, enabled them to achieve better solutions for complex mould making challenges. Here we see the partners with apprentices Richmond Tolotyi, Thebang Molapo at their toolroom in Bonaero Park, East Rand. Tooling @ Work specialises in moulds for gear components PHOTO: LOWRIE SHARP

rebuilds, as well as quality control. During this time he underwent training at Porsche in Stuttgart and qualiﬁed as a master technician certiﬁed by Porsche AG (Germany). A decade later, in October 2008, he moved to India to do after-sales development for new Porsche dealers around India. He was responsible for technical training and technical assistance and the full set-up of Porsche’s systems for India. His contract ended in September 2011 and he returned to South Africa, opting for the new challenge with SES where he is now responsible for the SKR project. Chris has implemented strategies employed at Porsche to the process at SES. For a start, the workshop is spotless! The goal is also to get the rebuild process completed in as short a time as possible and SES now possesses a production line scale system at its new, larger workshop in Wadeville (the company moved to larger premises in 2012). SES is the SA agent for Ferromatik Milacron, selling its complete range of machines, and also supplies its own range of SKR machines. A lot of the work at present involves rebuilds of older Ferromatik machines which feature exceptionally sturdy frames, tiebars and hydraulic components.

which produced high-pressure die castings and plastic injection moulds for a large and diversified customer base. Two years later, in 2002, when the company relocated to KZN, they went their separate ways, with each establishing their own tool and die making businesses. Logic suggested, however, that it would make sense for them to pool their technical expertise and infrastructure, and this led to the formation of Tooling @ Work in January 2006. This enabled the partners to provide their growing customer base with a more holistic service Both Stephen and Nelson have maintained valuable business relationships with their customers since 2000, providing continuity and sound understanding of their specific technical and design needs, critical factors in a production line. Both partners are hands-on involved in the day-to-day running of the business from a mould design, costing, planning, procurement, manufacturing, quality assurance and logistics perspective. They participate in client briefs and advise on overall functionality of products, including dimensions, materials and closures. Specialist facilities are used for steel hardening, cylindrical and profile grinding to ensure tight tolerances. • PHONE 011 395 2170 toolingatwork@vodamail.co.za FEBRUARY / MARCH 2013 17

Pride of place at SES is occupied, virtually on a production line basis, by machines which are either wholly rebuilt or assembled from scratch – which created the need for more space. Here we see Chris Kemp, manager of the machine rebuild business at SES in Wadeville, with a recently refurbished Ferromatik machine

www.sescc.co.za

Local PET plastic recycler continues to improve quality standards FOLLOWING the British Retail Consortium (BRC) audit which Extrupet’s bottle-to-bottle (B2B) manufacturing facility in Wadeville undergoes annually during October, not only was the state-of-the-art facility re- accredited, but it also managed to improve its status from a B grade to an A grade. The BRC accreditation guarantees brand owners that packaging made from PhoenixPET- the rPET resin manufactured at Extrupet’s newly A Grade ranking plant - meets the EU’s stringent food safety standards, and that the integrity of the product contained therein will not be compromised in any way.

According to Extrupet’s B2B plant manager, Krishna Doraisamy: “A Grade means that during the BRC audit process, the plant did not have any non-conformity of a critical or major nature against the statement of intent of a fundamental requirement. This is the highest grade that any rPET used in the ‘food packaging of high hygiene’ category can achieve. It ensures that not only is the resin produced in a hygienic environment, but that the quality and performance which are functional properties, is effectively managed to meet the appropriate speciﬁcations”. www.phoenixpet.com

A section of Extrupet’s main recycling plant. Whilst it is not the B2B plant, it is the plant where the PET recycling process begins and where rPET is manufactured before being transferred to the B2B plant where it is further processed and converted into PhoexnixPET PHOTO: PETCO

DPI Plastics technical and product manager Renier Snyman

4km mPVC pipe for Free State INDUSTRY NEWS

Ultraflo PVC pressure pipes supplied to large water supply project INCLEDON has supplied a large water supply line project in the Free State with a total of 4km of Ultraflo pipes manufactured in-house by DPI Plastics. DPI Plastics technical and product manager Renier Snyman points out that the company’s range of Ultraflo pipes are manufactured from modified polyvinyl chloride (mPVC), which is specifically designed to provide similar tensile strength and greater resilience than standard PVC piping products. “The Ultraflo range of pressure piping

systems are ideally suited to bulk water supply projects, due to the fact that mPVC is considerably more ductile than industry standard unplasticised polyvinyl chloride (uPVC),” he explains. Snyman notes that the ductility of the Ultraﬂo uPVC piping system ensures that the pipes have exceptional resistance to crack propagation under pressure. “The product being supplied to the water supply line project is the 500mm Ultraﬂo system, the largest in the DPI Plastics range. It boasts a pressure rating of 12 bar,

with a design stress of up to 18MPa, making it ideally suited as a large underground piping system.” The DPI Plastics range of Ultraﬂo piping products are available in pressure classes varying between 6 bar and 25 bar, and are supplied in standard 6 m lengths, complete with spigot, integral socket and rubber ring seal for user friendly installation.

www.dpiplastics.co.za

PET recycling capacity in USA exceeds collection volumes A RISE in the number of new PET recycling facilities in the United States means the country now has 10% more capacity to process post-consumer PET packaging material than it currently collects. And at 800,000 tons, PET recycling capacity in the USA is nearly double the amount of PET that was actually recycled 2012 was the ﬁrst year that PETCO faced a potential shortage of end-use market applications for recycled PET as the local bottle-to-ﬁbre market neared saturation and local recyclers approached capacity

in the country in 2011. According to the National Association for PET Container Resources’ (NAPCOR) latest annual recycling report, the new capacity which came on line in 2012, even if no PET bales were exported, meant these reclamation assets were short of material. The number of PET recycling plants in the US increased from 19 at the beginning of 2011 to 23 by the end of 2011. This boosted total annual capacity by more than 27%, from, 620,000 up to 800,000 tons – in other words, substantially more than the 720,000 tons of PET collected in 2011. (Source: Mike Verespej, Plastics News) 2012 turning point for PETCO’s development Meanwhile, Cheri Scholtz, CEO of PETCO, the South African industry body for recycling of PET, said that 2012 was

the ﬁrst year that PETCO faced a potential shortage of end-use market applications for recycled PET as the local bottle-to-ﬁbre market nears saturation and local recyclers approached capacity. In 2011 PETCO achieved an annual PET recycling rate of 42% of post-consumer beverage PET and 29% of total PET, with 42 651 tonnes of PET collected and recycled out of a 145 000 tonne 2011 local market. For 2011, the tonnage collected and recycled including pre-consumer was 46 276 tonnes, representing 46% of beverage PET and 32% of total PET. The 2012 PET recycling results are being audited at present and are not yet available for publication, but the target for the year is 44% of post-consumer beverage PET in an anticipated local market size of 160 000 tonnes. www.petco.co.za

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INDUSTRY NEWS

Pilot project to recycle contaminated, coloured, black polystyrene Patented chemical mixture uses recycled scrap polystyrene to create solid wall system for construction industry

PHOTOS: LOWRIE SHARP

A PILOT project that has found a viable end-market for contaminated, coloured and black polystyrene has been launched. The joint venture between GC Construction (GCC), the Mobile Educational and Training Trust (NPO) and the University of Pretoria’s Construction Economics Faculty has created a viable end-market for contaminated polystyrene using a patented IP. The pilot project was revealed to Polystyrene Packaging Council (PSPC) guests recently at a highly successful open day at the Plastics|SA head ofﬁce in Midrand. More than 100 guests representing various aspects of the local recycling and plastics industries, as well as product developers and the media were treated to an informative morning which included a site visit to WastePlan’s new factory in Watloo, Pretoria, where they witnessed the recycling process ﬁrsthand. “Clear, colourless or white polystyrene has always had the highest recycling value, with waste management and recycling companies preferring to collect and recycle unpigmented containers,” explained Hennie Snyman, representing GCC and the NPO. “However, we have developed a global patented chemical mixture that uses recycled scrap polystyrene – including coloured, black or contaminated polystyrene – to create a solid wall system for use in the construction industry”.

Hennie Snyman, representing GC Construction (GCC), the Mobile Educational and Training Trust (NPO), with Adri Spangenberg, PSPC director and Ivan Ortlepp, PSPC chairman and MD of CibaPak 20 FEBRUARY / MARCH 2013

Kevin Matthews of Akura, manufacturers of the baling machine seen in the photo, explains how the polystyrene waste is made into bales. Lorraine Botha of Akura Durban looks on. The PSPC has teamed up with waste management machinery manufacturer Akura to supply its machines and auxiliary equipment, which include baling presses, static compactors for supermarkets and retail shopping malls as well as complete municipal waste transfer stations

GC Construction (GCC), the Mobile Educational and Training Trust (NPO) and the University of Pretoria’s Construction Economics Faculty have developed a global patented chemical mixture that uses recycled scrap polystyrene – including coloured, black or contaminated material – to create a solid wall system for use in the construction industry

Used polystyrene baled and ready for recycling

Launched towards the end of 2012, the joint venture between GC Construction (GCC), the Mobile Educational and Training Trust (NPO) and the University of Pretoria’s Construction Economics Faculty has created a viable end-market for contaminated polystyrene using a patented IP

Impressive test results from SABS Snyman shared the impressive test results obtained from the SABS. “The SABS subjected the GCC and METT patented chemical mixture to a series of tests, from fire and water penetration tests to load-bearing, impact and stress tests. The results were off the charts and were met with unprecedented success. This was the first time in history that polystyrene had sustained heat at 1800ºC,” he added. After a two-hour fire test, using 15 000 litres of diesel, the tested panel remained intact. Following the completion of the test, the outer temperature of the polystyrene waste and chemical panel had dropped 21ºC from the start of the test to two hours in the furnace.

Adri Spangenberg at WastePlan near Mamelodi, north of Pretoria, discussing the methods of household waste polystyrene collection and the sorting process which happens before the different PS types are baled and supplied to the many enterprising people who create useful products

municipal waste transfer stations. “As soon as GCC needs material, we will be ready to supply,” Spangenberg said.

Measures in place to improve collection To this end the PSPC has put certain Go-ahead from government to build measures in place to improve collection one million homes from households and transportation of the GC Construction has received the goproduct. ahead from government to contribute to “Two balers have been installed at the construction of one-million houses in separate waste management sites in Africa using the patented chemical mixGauteng – national onsite waste manageture, which is moulded into panels. Each 1200cm x 500cm panel is made from 12kg ment company WastePlan in Pretoria and ABSA Capital in Sandton, which collects of polystyrene, waste and chemicals. polystyrene waste from its own cafeteria “We are going to need polystyrene – a and those in surrounding buildings to be lot of it – and the best thing about it is that baled and shipped for we need real rubbish,” recycling.” SpangenSnyman said. Go ahead from berg said. The company’s government to contribute “The PSPC also inﬂagship factory is to the construction of stalled a granulator at based in Pretoria Remade Recycling, and became fully one-million houses in an independent multioperational in October Africa using the patented product recycling 2012. However, due to chemical mixture, which is company, to supply the speed at which the moulded into panels Hennie and his team project is developing, with granulated polythe company has styrene that we’ve collected from factories already had to move to larger premises. and large retailers”, she added. The factory currently houses a 375-litre Snyman said that GCC will be opening mixer which can make up to 90 wall panthree factories in each of South Africa’s els a day with plans to install two bigger nine provinces to manufacture the wall 5000-litre mixers later this year. panels and other construction materials The PSPC has also teamed up with that can be moulded from the patented waste management machinery manumixture. However, to keep the intellectual facturer Akura to supply its machines property safe, the GCC and METT dry and auxiliary equipment, which include chemical mixture will be mixed and packbaling presses for the recycling industry, aged in Pretoria and sent to the various static compactors for supermarkets and factories across the country. retail shopping malls, as well as complete

Franchise-based job-creation project “It’s going to be a franchise-based jobcreation project controlled by GCC and METT which hold the intellectual property of the product,” Snyman explained. “We will be rolling out the project across South Africa and the rest of the continent as soon as licenses are issued to interested parties. Once the licenses and relevant paperwork are in place and the relevant machinery installed, there is no reason why factories would not be able to open up immediately,” Snyman said. Whilst careful to commit to a speciﬁc date, Snyman said that four licenses would be sold very soon in Africa and that he was conﬁdent in the product and the speed of construction at which these houses will be constructed. Meanwhile, data and statistics from the installed balers and granulator are being gathered for use in business plans for potential waste management companies. “The PSPC will use this information to help new companies and entrepreneurs who would like to start collecting polystyrene to generate income,” Spangenberg said. “We will be able to assist them with a business plan so they know what kind of machine they need and what volumes they need to consider. As the PSPC, we will support them, assist with marketing and ensure that they get the materials for their machines”. www.polystyrenepackaging.co.za

Waste not ... all these products have been made from recycled polystyrene, including comfy beanbags from PANDA products; seedling trays manufactured from recycled PS by Groplast and ﬂoating pool pillows from www.poolpillows.co.za FEBRUARY / MARCH 2013 21

INDUSTRY NEWS

The group was founded in 1952 by Romanos Romano whose ﬂair for design and willingness to take on any job led to a steady growth in the business

Celebrating 60 years in signage Top user of plastic sheeting for signage for six decades ONE of the pioneers of the South African signage industry, the Romano Group, celebrated 60 years in business last year. Romano has been one of the top users of plastic sheeting for signage, especially outdoor signage, for six decades. The group was founded in 1952 by Romanos Romano who’s ﬂair for design and willingness to take on any job led to a steady growth in the business. Initially the focus was signwriting, however, soon the company started producing “5-by-2’s” (5-feet long and 2 feet high under-awning signs with ﬂuorescent lamp illumination). Over the years the company has

always stayed abreast with the latest technologies available to the signage industry and adopted these into the business. These included ﬂuorescent and neon-illuminated signs (1950’s); engraving, acrylic fabrication and moulding (1960’s); screen printing and metal fabrication (1970’s); CAD/CAM - including computerised router and vinyl cutting (1980’s); digital printing (1990’s); and LED and ECG-based ﬂuorescent illumination (2000’s). In recent years, based on the needs of Romano’s client base and the company’s internal strengths, the company expanded its product range to include solar photovol-

taic (PV) energy systems, signage & print, eco lighting and modular construction. Although Romanos Romano missed the technological changes taking place after his death in 1993, his son Alexi Romano (the Romano Group’s current CEO) credits the growth and success of the business to the “incredible energy and passion” of his late father, combined with the hard work and dedication of the Romano Group’s employees, both past and present.

www.romano.co.za

Over the years the company has always stayed abreast with the latest technologies available to the signage industry and adopted these into the business. These included ﬂuorescent and neon-illuminated signs (1950’s); engraving, acrylic fabrication and moulding (1960’s); screen printing and metal fabrication (1970’s); CAD/ CAM – including computerised router and vinyl cutting (1980’s); digital printing (1990’s); and LED and ECGbased ﬂuorescent illumination (2000’s)

DPI Plastics returns to profitability in 2012 DPI Plastics increased revenue substantially during the course of the 2012 financial year, ensuring a return to profitability for the first time in three years. DPI Plastics forms part of the Dawn Group which specialises in the manufacture and distribution of quality branded hardware, sanitaryware, plumbing, kitchen, engineering and civil products. DPI Plastics managing director Gerhard Kotzee attributes this dramatic turnaround

22 FEBRUARY / MARCH 2013

to the company’s restructuring strategy, in addition to improved conditions in the infrastructural sector of South Africa. According to Kotzee, an increase in government tenders issued played an important role in improving market conditions during 2012. Kotzee is optimistic that DPI Plastics can consolidate on its current successes in 2013 and beyond, as South Africa is expected to undergo an infrastructure

development boom in the short-term future, DPI Plastics MD following plans set out Gerhard Ko tzee by the Presidential Infrastructure Co-ordinating Commission to develop key strategic infrastructure projects, estimated to be worth more than R4-trillion over a 15 year period. www.dpiplastics.co.za

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ASSOCIATION NEWS

New PVCMedAlliance to promote medical use of vinyl Vinyl can reduce risk of life-threatening, healthcare acquired infections THE newly formed PVCMedAlliance, an industry alliance of PVC resin and plasticiser producers and converters, has set out to highlight the many advantages that exist when using vinyl in the healthcare environment, most notably its ability to reduce the risk of life-threatening and healthcare acquired infections. The alliance, which was launched at the Global Vinyl Council (GVC) in Florida, USA in November, aims to raise the international

awareness of vinyl usage and its value in the healthcare industry. â&#x20AC;&#x153;The PVCMedAlliance is a signiďŹ cant milestone for vinyl around the world,â&#x20AC;? says Delanie Bezuidenhout, CEO of the Southern African Vinyls Association (SAVA). â&#x20AC;&#x153;The alliance will go a long way in encouraging dialogue within the industry, particularly with regards its use in the medical industry.â&#x20AC;? She explains that vinyl is used far more extensively in the medical industry than just

for blood bags, tubing and artiďŹ cial skin. It is also used for items such as ďŹ&#x201A;ooring, cupboards, plumbing pipes, electrical wiring and bed coverings. Furthermore by adding plasticisers to vinyl, one is able to produce a product that is soft and ďŹ&#x201A;exible which dramatically improves both safety and comfort. â&#x20AC;&#x153;It will be part of the allianceâ&#x20AC;&#x2122;s role to continuously highlight the quality, safety and environmentally responsible uses of vinyl within the healthcare environment as well as

SAVAâ&#x20AC;&#x2122;s 3rd AGM attracts industry guru DR JASON Leadbitter, renowned industry expert from the UK, will be the guest speaker at the 3rd AGM of the Southern African Vinyls Association (SAVA) which takes place at Plasticsâ&#x201D;&#x201A;SA Auditorium in Midrand on 27 February. Dr Leadbitter who has 23 years working experience in the vinyl indus-

try, currently holds the position of Sustainability and Compliance Manager at INEOS ChlorVinyls, Europeâ&#x20AC;&#x2122;s largest vinyl producer. â&#x20AC;&#x153;Dr Leadbitterâ&#x20AC;&#x2122;s attendance at our AGM is a coup for SAVA,â&#x20AC;? comments Delanie Bezuidenhout, SAVA CEO. â&#x20AC;&#x153;With our Association being in its infancy we are thrilled to have

24 FEBRUARY / MARCH 2013

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attracted such a lauded industry spokesperson whose tremendous knowledge can be shared with our growing membership base.â&#x20AC;? SAVA membership is open to corporate bodies and select individuals. Playing an active role in various European trade associations that deal with en-

Importance of â&#x20AC;&#x2DC;Best Practiceâ&#x20AC;&#x2122; PVC products ENVIRONMENTALLY conscious building contractors and architects can beneďŹ t from making use of PVC piping products produced by companies that are recognised by SAVA as â&#x20AC;&#x2DC;Best Practice PVC Manufacturersâ&#x20AC;&#x2122;. In January 2012 DPI Plastics became recognised by SAVA as a Best Practice PVC manufacturer after becoming a signatory of the associationâ&#x20AC;&#x2122;s Product Stewardship Programme (PSP), which is a series of achievable commitments to address the industryâ&#x20AC;&#x2122;s environmental issues. DPI Plastics technical and product manager Renier Snyman notes that the company has gained considerable market interest from potential clients looking to obtain a green star rating from the Green Building Council of South Africa (GBCSA). According to Snyman, DPI Plastics has also committed itself to the SAVA targets for the national PVC industry of increasing recycling of post-consumer PVC-P to 15 000 tons per annum, while increasing recycling of post-consumer PVC-U to 5000 tons by January 2013. www.dpiplastics.co.za

to promote the research and development within the industry which will ultimately create even more uses for the material,â&#x20AC;? explains Bezuidenhout. The PVCMedAlliance will also: Produce and promote relevant scientiďŹ cally-based information on vinyl use in healthcare. Provide a focal point for communication between regulators, the medical and healthcare community. Empower PVCMed members with targeted and appropriate material and messages. Promote partnerships with third parties to promote innovative, environmentally responsible practices with regards vinyl usage and management within healthcare industry. Founding members of PVCMedAlliance include BASF; Colorite Europe; Eastman; ECVM; OXEA; Renolit and Tarkett. www.savinyls.co.za

vironmental and waste management issues, Dr Leadbitter is also the current chairman of the Controlled-Loop Recycling Committee of VinylPlus â&#x20AC;&#x201C; the European PVC industryâ&#x20AC;&#x2122;s voluntary commitment. In addition he is a respected author of several books and publications dealing speciďŹ cally with sustainability. The public results from the ďŹ rst SAVA Product Stewardship Programme (PSP) survey will also be announced at the AGM.

SAVAâ&#x20AC;&#x2122;s PSP consists of a series of achievable commitments to address the vinyl industryâ&#x20AC;&#x2122;s environmental issues

Dr Jason Leadbitter

â&#x20AC;˘ FOR SAVA AGM BOOKING INFORMATION CONTACT DELANIE BEZUIDENHOUT DELANIE@SAVINYLS.CO.ZA www.savinyls.co.za

FEBRUARY / MARCH 2013 25

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ASSOCIATION NEWS

Plastics conference addresses industry issues with lively debates THE South African plastics industry will be debating various issues that impact on its growth and future prospects with the ﬁrstever industry speciﬁc conference, hosted by Plastics|SA. Aptly entitled ‘Plastics: The Future for Growth’, this one day conference will take place on Wednesday, 13 March and promises to be one of the highlights of this year’s Pro-Plas Conference at the Nasrec Exhibition Centre, south of Johannesburg. “We are very excited about hosting a conference that will create a platform for open

dialogue, the sharing of ideas and soliciting of various opinions on issues that affect our industry”, says Plastics|SA executive director, Anton Hanekom. “We have deliberately tried to move away from the traditional approach to conferences. Instead of the regular speakers addressing audiences on old topics, we will be having three lively debates during which well known, investigative journalists will lead a panel of experts in discussions. “Thanks to the use of technology, delegates will be able to inﬂuence the discussions

taking place on the stage by electronically sending their questions and comments to the moderator, or by voting on issues being discussed, in real-time,” Hanekom explains. The conference will consist of the following exciting line-up: Opening keynote address by Dr Wilfried Haensel, executive director of PlasticsEurope, sponsored by Engen Petroleum Debate 1: “Growing the South African Plastics Industry”, sponsored by Sasol Polymers and moderated by Freek Robinson

21st IOM3 conference promises diverse range of topics THE 21st National Rubber Conference will be held at the Cape St Francis Resort and Conference Centre in the Eastern Cape from 8-10 March. The list of speakers and topics so far includes: Dr Phil Bischler, Institute of Materials, Minerals & Mining will open the conference. Colin Clarke, Schill + Seilacher, will present on ‘New Functional Additives offer Increased

Process Optimisation and Property Improvement for Highly Loaded Compounds’. Ulf Czesla of Münch Chemie International GmbH will present ‘The Release Agent Specialist’ Dave Duncan, Anton Hanekom and Tony Hesp will debate ‘Recent developments in the Education and Training in the South African Rubber Industry’

Stewart Knight, REP International, will talk about ‘Bladder Moulding for the Tire Industry’ Ian Latchem, HF Mixing Group, will present ‘Upgrading existing Tangential Mixing Lines’ Bernhard Schwaiger, Orion Engineered Carbons GmbH, will discuss ‘Performance Enhancement in Rubber by

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New chairman for Plastics |SA Lunch, sponsored by Safripol Debate 2: “What impacts on plastics packaging?” sponsored by Polyoak Packaging and moderated by Jeremy Maggs Debate 3: “Are plastics sustainable?” sponsored by PETCO and moderated by Ruda Landman Cocktail function and awards ceremony sponsored by ColorMatrix, a subsidiary of PolyOne Corporation. Registrations are already in full swing and can be done online at: www.plasticsinfo.co.za

Tailored Carbon Blacks ‘ Olivier Segonds of Safic Alcan Products will present ‘DOTG Replacement and other Safic Products for AEM and ACM Formulations’ Hennie Strydom of Akzo Nobel will discuss ‘Enhanced Scorch Safety in Peroxide Cure’ Aart van der Pol of VMI will talk about ‘Application of Gearpump Extruders’ Dr Chris Woolard of Sasol will explain ‘The Influence of Biofuels on Alcohol-

Golf at Modder, 28 February PISA Northern branch is hosting a golf day at Modderfontein on Thursday 28 February which is aimed at being a fun, social and networking event. So, if you have clubs, get them out and swing them. Inquiries to either Horst Seute, 083 676 0278 Lowrie Sharp, 011 793 4691 Brian Sinclair, 082 559 8770 based Fuels on Rubber Sealing Materials’ Tzu-Hsing Yen of Tung Yu Hydraulic Machinery Co. Ltd will present a paper on ‘Rubber Vulcanizing Equipment for Mining Industry – Manufacturer of Jumbo size Vulcanizing Machine, Rotocure and Steel Cord Conveyor Belt Production Line’ For further information, contact Wendy Knott-Craig at 073 201 8699

THE new board that will take Plastics |SA forward this year has been elected with Philip de Weerdt, group executive of Nampak Rigid Plastics |SA ’s new chair Plastics, as the new man, Philip de Weerdt chairman, taking over the reins from Jeremy Mackintosh of Polyoak Packaging. “I’m looking forward to working in partnership with the new Plastics|SA board to continue the exciting and challenging journey to grow and support the South African plastics industry. We don’t know what the future holds, but I can assure you that plastics will be part of it,” said Anton Hanekom, executive director of Plastics|SA. Other members of the executive committee are: Anton Hanekom (executive director), Cheri Scholtz, Kirtida Bhana (training executive), Jeremy Mackintosh (vice chairman), Douglas Greig (vice chairman), Douw Steyn (director for sustainability), Thokozani Masilela, Monya Vermaak (marketing and communications).

FEBRUARY / MARCH 2013 27

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ASSOCIATION NEWS

Supersonic ‘car’ aims to hit 1700kph! Rocket and jet powered vehicle to fly across Northern Cape pan AN EXTREME automotive project which is England, has some startling stats: its mopushing the frontiers of science and technol- tors can generate a staggering 135,000 ogy, the Bloodhound SSC (supersonic car) horsepower; it will use about 7.5 tons of fuel programme is creating interest in the most and over a ton of hydrogen peroxide for the unlikely of places … like the harsh ‘vlakte’ of approximate 20km dash (which has to be the Northern Cape. repeated within an hour of the first outing); Yep, Hakskeenpan in the Kalahari is the its wheels rotate at 10,300 rpm and it can venue where the jet and rocket propelled accelerate at 95kms per second … and the Bloodhound vehicle will attempt to break list goes on. the world land speed record later this year. This ultimate racing car can accelerate Speeds in the region of a terrifying 1600kph from 0 to 1609 km/h and back to zero in just are expected! To 120 seconds while confirm, yes that is handling the phenomWith a car capable of 1700kph – which is enal forces and loads speeds of over 1600kph, faster than the speed acting upon it such the main challenge is to of sound. as 21,000kgs thrust prevent it from taking off Over 50 sites (equivalent to 180 F1 around the globe cars) generated by its were considered for the speed trial, with the jet and rocket engines; 30 tonne suspension 20km-by-4km Hakskeen coming out tops. loadings for its solid aluminum wheels, each The pan had the advantage that it fills weighing 105kg spinning at 10,200 rpm and with water annually, whereas many of the generating an extraordinary 50,000 G at the other pans were presumably too dry. Stone rim. clearing on the surface of the pan created With those sort of stats, it’s obvious that the temporary work for about 300 people in the main challenge is to prevent the vehicle from region. taking off. It will be travelling faster than jet linThe car, which is being built in Bristol, ers! The SSC will be driven by Andy Green of

Royal Air Force ofﬁcer Andy Green set the current land speed record of 1228 kilometres per hour in October 1997

England, the current holder of the world land speed record of 1228kph, set with the Thrust SSC in 1997. With its mission being to ‘confront and overcome the impossible using science, technology, engineering and mathematics,’ the Bloodhound project was founded by a number of British learning establishments and has the intention of “raising the visibility of engineering,” said guest speaker Dave

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Scale model of the vehicle downplays its size: the SSC is 13.4m long, 2.8km high and 1.8 wide.

Rowley, at a Western Cape Tooling Initiative presentation in Cape Town in November. The Bloodhound founder members include the University of Swansea, University of West England and Britainâ&#x20AC;&#x2122;s Engineering & Physical Sciences Research Council. Joining at the outset in 2008 were STP (engine fuel additive supplier) and Serco group (supplier of public services to governments internationally). Since that time, however, the speed enthusiasts involved have had to undertake fundraising to quite literally fuel the project. Setting the record will be a tough challenge: the vehicle has to make two runs, in opposite directions, within one hour of the ďŹ rst run, so itâ&#x20AC;&#x2122;s going to be tough. www.bloodhoundssc.com

Dave Rowley of the Bloodhound Education programme, who gave the presentation about the â&#x20AC;&#x2DC;rocket shipâ&#x20AC;&#x2122;; British consul-general Christopher Trent; and John McEwan, director of the Western Cape tooling initiative FEBRUARY / MARCH 2013 29

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g i b e h T trek! SOCIAL change adventurers, Michael Baretta and Camilla Howard are trekking 3000km along SA’s coastline to increase awareness about littering. The couple were inspired to start the CAN DO! ‘Trekking for Trash’ initiative after realizing how much litter goes unnoticed. They started walking in October last year

from Alexander Bay on the Namibian border and plan to finish in Kosi Bay on the Mozambican border. The complete journey will take an estimated seven months to complete. During the first three days of the expedition, Michael and Camilla covered 95km and collected five bags of litter, each weighing between 10 and 15kgs. Nampak Bevcan, Nampak DivFood and Collect-a-Can are sponsors of ‘CAN DO! Trekking for Trash’. The majority of the litter collected so far has been from glass and plastic bottles that were presumably thrown out of car windows by passersby. By mid-January (when this article was penned), Michael and Camilla had reached the halfway point of their trek, Knysna on the Garden Route, having walked about

The Trekking for Trash duo, Camilla Howard and Michael Baretta, have enjoyed some light moments on their trash collecting traverse of the SA coastline, here they relax in a dingy on the west coast

1500km and collected 2.5 tons of litter so far. “We are challenging other corporates to pledge their support in making a difference to environmental awareness in South Africa,” said Erik Smuts, MD of Nampak Bevcan. “Through the funding scheme, money raised will be donated to environmental education organisations as we believe in the importance of communicating the negative impact litter has on our environment and how we all can make a difference to improve our country.” www.trekkingfortrash.co.za

30 FEBRUARY / MARCH 2013

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PE pellets a useful monitor of

POPs in marine systems International Pellet Watch uses PE pellets as passive samplers lutants to concentrate in plastic particles RESEARCH recently completed revealed can be used to monitor the distribution and that concentrations of Persistent Organic abundance of bio-accumulative and persisPollutants (POPs) in marine systems along tent compounds in marine environments. the South African coast have decreased The International Pellet Watch (IPW) over the last two decades. And providing was set up in 2005 to identify key source the most useful tool to help monitor this deareas and potential violations of international crease in POPs were polyethylene pellets! regulations controlling PE pellets collected the use of bio-accumubetween 1984 and Repeated sampling of lative and persistent 2008 at three South polyethylene pellets from the compounds. It uses African beaches were same site has the potential polyethylene pellets analysed for PCB, HCH to track temporal changes as convenient passive and DDT. The studies in these compoundsâ&#x20AC;&#x2122; samplers to assess revealed that concentraenvironmental loads of tions of all three POPs concentrations in marine these compounds in decreased over the last environments coastal waters around two decades. The study the world. demonstrates the potential for International Polyethylene pellets are preferred bePellet Watch to track temporal as well as cause they are more efďŹ cient at accumulatgeographical patterns in the abundance of ing persistent compounds than other plastic POPs in marine environments. polymers such as polypropylene. The research paper* notes that there is In addition to tracking geographical patgrowing concern about the ubiquitous nature terns in bio-accumulative and persistent of plastics in the environment, especially in compounds, repeated sampling of polymarine systems. One of their impacts is to ethylene pellets from the same site has transport a suite of persistent toxic pollutthe potential to track temporal changes in ants and to introduce them into marine food these compoundsâ&#x20AC;&#x2122; concentrations in marine webs when animals ingest plastic particles. environments. The tendency of hydrophobic organic pol-

Of the pellets from each beach in each year, 82% were polyethylene, 11% polypropylene and 7% other polymers. The proportion of polyethylene pellets decreased over the sample period at all three beaches, averaging 86% in the 1980s and 1990s, decreasing to 77% after 2000. Overall, median concentrations of all POPs in pellets decreased from the 1980s to 2000s. * Ryan, P.G., et al. Long-term decreases in persistent organic pollutants in South African coastal waters detected from beached polyethylene pellets. Mar. Pollut. Bull. (2012), http://dx.doi.org/10.1016/j.marpolbul.2012.09.013 Authors: Peter G. Ryan a, Hindrik Bouwman b, Coleen L. Moloney c, Masaki Yuyama d, Hideshige Takada d. a) Percy FitzPatrick Institute of African Ornithology, DST/NRF Centre of Excellence, University of Cape Town, Rondebosch 7701, South Africa b) School of Environmental Sciences and Development, North-West University, P. Bag X6001, Potchefstroom 2520, South Africa c) Marine Research Institute and Department of Zoology, University of Cape Town, Rondebosch 7701, South Africa d) Laboratory of Organic Geochemistry (LOG), Tokyo University of Agriculture and Technology, Fuchu, Tokyo 183-8509, Japan FEBRUARY / MARCH 2013 31

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INDUSTRY NEWS

Proplas Africa will be main 2013 event for region Over 40 of SA’s equipment, materials and services supplier to exhibit PROPAK Africa, South Africa and one of Africa’s premier packaging and plastics shows, hasn’t been held since 2009, but the wait has only increased interest in the event. The 2010 edition of the show was held earlier than planned due to fears that the country would be swamped by soccer fans attending the soccer World Cup that year. Wisdom gained since suggests that few soccer fans would have attended the

soccer ﬁesta – very few actually – and that the country’s tourism infrastructure would more than easily have been able to cater for trade show travelers that year. Nonetheless, a lot is expected of the main Propak Africa event and its subsidiary Proplas Africa, running at the Nasrec Expo Centre in Johannesburg from 12-15 March. The Specialised Exhibitions shows – along with the tandem events Print Expo, Pro-Label Africa and FoodPro – return to their former three-yearly routine, another

change being that it is being held in March again … but the longer interval seems to have only increased interest. The Proplas event has attracted more interest than ever before and South Africa’s plastics equipment, material and services supply sector has risen to the occasion, with over 40 SA companies joining an estimated 80 other exhibitors in what promises to be the main event of the year for the industry in southern Africa. Here we preview the exhibits of some of the main local participants:

Adex to show wide range of equipment WITH more than 30 years’ experience, Adex Plastics & Machinery will be exhibiting equipment from its principals: Windsor (manufacturer of mono and multi-layer blown film lines, pipe and profile lines, blow moulding equipment, and compounding lines); SGI (advanced technology air rings and corona treaters); Pelican Rotoflex (flexographic equipment, including stack, CI and gravure presses, slitter-rewinders, solvent and solvent-less laminators); GM (recycling lines, shredders, granulators and pelletizers); Mamata (high-speed, side weld and universal bag makers, pouch makers, wicketers); CMD (bag-on-roll systems and bottom-seal bag makers); Sysmetric (gravimetric dosing, loss-in-weight feeding and line control systems for blown film and pipe extrusion lines).

A high-speed Soloslit 3500 slitter-rewinder from Pelican Rotoﬂex will be shown on the Adex stand. Processing 1250mm wide ﬁlm at more than 400m/min, the ability to conduct remote diagnostics and programming of the slitter over the internet will be demonstrated. For example, the unit can be in operation at a customer’s premises in South Africa and a technician can make adjustments from his desk at the Pelican works in Rajkot, India

Adex: stand C15 Hall 5

Simpler, leaner process to colour match from ColorMatrix COLORMATRIX will highlight its extensive liquid colour and additive technologies portfolio. Formulated using the latest generation carrier systems, ColorMatrix liquid dispersions incorporate more effectively into the polymer achieving higher quality, more consistent colour distribution and superior aesthetics. Highly accurate dosing can be achieved

– down to addition rates as low as 0.001% when these liquid technologies are metered with the company’s state-of-the-art volumetric dosing equipment, improving inventory control and reducing waste. Processors can improve sustainability and cost efﬁciency with higher letdown ratios that require less colorant or additive, minimising raw material consumption while enabling smoother and more efﬁcient processing. Liquid colour formulations and customised dosing equipment are designed to facilitate quick, simple colour changes that minimise machine downtime.

ColorMatrix has focused more recently on improving its rapid colour development capability. The DosiXpress™ colour matching cell is able to help customers streamline product development and speed up commercialization. A hand-held spectrophotometer is used to perform an instant colour match and produce a sample for trials or a small production run in a matter of minutes. ColorMatrix: stand G38 Hall 5

ColorMatrix as a DosiXpress™ colour matching cell at its facility in Cape Town to provide rapid colour development for customers. 32 FEBRUARY / MARCH 2013

Intelligent vision inspection INTELLIGENT Inspection Systems (i2S) manufactures vision inspection equipment for a large variety of applications. Based in Johannesburg with a local and international client base, the company develops optical electronic systems using intelligent video imaging technology for industrial QC and automation systems. The i2S technology has been installed on OEM systems on over 800 applications in plastic closure factories in Europe. I2S has installed more than 1500 custom-built vision systems for various applications in factories throughout Africa, the Middle East, Europe and North America. At Proplas, I2S will be presenting its Intelligent Inspection Systems stand-

Continental Compounders CONTINENTAL Compounders are acting on their commitment to the South African Vinyls Association (SAVA) and are in the process of ensuring that their plant in Durban will be totally heavy metal free (HMF) by the end of April.

The stand-alone cap sorter (left) with the cap cooler and waterfall feeder from Italian partners Green Box for which Intelligent Inspection Systems is the SA agent

alone cap sorter. With its efﬁcient design, small footprint, low input power, high precision transport mechanism and 0.5 mm repeatable orientation under camera, uniform inspection is guaranteed. Also on show will be a cap cooler and waterfall feeder from I2S’ Italian partners

“This is a strong commitment to SAVA initiatives and to our industry as a whole,” says MD George Dimond. “It is our drive that PVC products and formulations in South Africa should emulate European and other world class industry standards; it’s the best way forward.” The project began in 2009. Continental Compounders have also launched an excellent range of Fainplast Specialised Compounds into the SA market;

Green Box, for which I2S is the South African agent. www.i2systems.co.za Intelligent Inspection: stand A23 Hall 5

including HFFR/crosslinkable compounds for energy, telecoms and solar panel wire and cable, backed by experienced technical knowledge and testing facilities. This innovative range will compliment Continental’s range of quality PVC products available. Continental: stand C27, Hall 5

FEBRUARY / MARCH 2013 33

Suppliers of PVC, Nitrile, Halogen Free and other Quality Compounds for a cleaner brighter South Africa. Contact us: Tel: +27 31 791 0600 Fax: +27 31 791 0081 Email: info@compounders.co.za www.compounders.co.za

A member of

INDUSTRY NEWS

Maritime to show wide range of equipment MARITIME Marketing and Maritime-Seecor will again have a signiﬁcant presence at the 2013 edition of Propak. It will be exhibiting and running a variety of machinery, supported by its international partners, ready to show you the latest technologies on offer, including: the latest injection moulding innovations from Engel Austria and TMC Taiwan single-station 5-litre blowvmoulding machine from SIKA of Taiwan 4-cavity PET re-heat blow machine from Urola of Spain Piovan material blending and conveying equipment;

range of Zerma granulators and shredders Limax-GAPA-1400 high-speed multilane bottomweld bag machine the popular Macchi ‘Recotrim’ edge-trim recycling unit Webcontrol 1600mm high-speed slitter/ rewinder recycling/pelletising line from Yea Jing of Taiwan; and high-performance wash-plant equipment from G.E.T. of China.

Rotary extrusion blow moulding technology from Urola of Spain will be on show on the Maritime stand

Maritime: stand C6 Hall 5

New ASB 12 M ‘one-step’ machine THE ASB-12M, a ‘one-step’ injectionstretch blow moulding machine which can produce jars and bottles directly from PET and other types of plastic resins in one machine, will be on show on the Nissei ASB stand. With the introduction of this machine to the ASB Series line-up, Nissei ASB offers a completely new solution to the many customers that have been requesting a large neck sized container from a small scale fully automatic machine.

The famous GAPA bag making technology, developed in SA, is now being utilized by Limax in Malaysia, where the inimitable Robbie Butschi is working his magic nowadays; one of the Limax-GAPA machines will be on show on the Maritime stand

Nissei ASB: stand B20

With the huge success and experience of the 100% built-in-India ASB-50MB entry model (that has now sold over 1700 units), Nissei ASB has designed and manufactured the ASB-12M with a combination of Japanese know-how together with the well proven quality and reduced cost of its Indian manufacturing unit. From parts procurement, process-

ing, assembling to moulding test, every process of production is carried out in ASB’s factory in India. While achieving reduced manufacturing costs, the machine has higher productivity, plus advanced speciﬁcations and functions such as vastly improved energy consumption. The ASB-12M is an all-new machine based on an amalgamation of the Indiamade ASB-50MB which boasts fantastic cost competitiveness, together with the higher speciﬁcation Japan-made ASB12N/10 with its excellent reputation for manufacturing a wide variety of containers in PET and various other plastic materials.

The new ASB-12M one-step injection stretch-blow moulding machine from Nissei ASB can produce jars and bottles directly from PET and other types of plastic resins in one machine; featured here, wide-mouth jars moulded on the ASB-12M

Dyna Purge solution from Keniplas

Mouldbase will be there

KENIPLAS will be introducing some exciting new suppliers and products. It will be launching the full range of Dyna-Purge® purging compounds manufactured in the USA by Dyna-Purge. Dyna-purge pioneered purging compounds over 30 years ago and is a market leader in this ﬁeld. The company’s International business manager, Kelli Ropach, from the USA, will be available for the full run of the exhibition to meet with prospective customers. Keniplas will also be introducing the range of lubricants, waxes, processing

MOULDBASE SA will exhibit high quality mould build-ups for the toolmaking industry. A variety of different styles are available and a comprehensive range of different sizes and conﬁgurations is available for immediate delivery countrywide. Preground tool steel inserts and a variety of mould components, swivel lifting points for use in injection moulding plants, as well as hydraulic and magnetic quick mould change systems are also available. These products and more will be on show at Proplas 2013.

FEBRUARY / MARCH 2012

aids, antistatic agents and PP clariﬁers produced by Liberty Chemicals India. Another participant on the Keniplas stand will be Varteco Argentina, showing a range of plasticisers for PVC including an economical bio-based plasticiser alternative for the PVC packaging industry. Also on the stand, high-performance engineering plastic compounds from Pontex Taiwan will also be introduced. Keniplas: stand G11 Hall 5

VISIT US AT PROPAK 2013 STAND 5 B23

INDUSTRY NEWS ®

Rawmac introduces Zislloy PA compounds from Taiwan RAWMAC, one of the top material suppliers to the industry in Southern Africa over more than three decades (established 1979), will be introducing its new principal Zig Sheng of Taiwan at Proplas. Zig Sheng has been involved in polyamide polymerization as well as the manufacture of spinning grade PA chip since 1970. It has capacities of 150,000tpa of polymerized PA and 120,000tpa of spinning grade chip. The group has steadily increased its output with successive plant expansions and now operates three PA polymerization plants and two spinning grades plants. In 1979 it became the ﬁrst company to introduce two-tone yarn that was at the time a revolutionary product for the draw

textured yarn sector, making it one of the leaders in the textile industry. In 2004 the company established its Zig Sheng R+D Centre, which marked the start of an intensive effort to develop engineering plastics. It is in this area where its compounding expertise has been extensively exploited: Zig Sheng is now a leading international compounder of specialised PA and polypropylene grades. Its range of Zislloy® polyamide compounds are used widely in the automotive, electronics, power tools and sports and consumer goods sector, where the advantages include: low friction, high stiffness, high toughness and excellent durability; hydrolysis, grease /oil, fatigue and

creep resistance; and high temperature capabilities. “We have been introducing the Zislloy range of standard PA6 and 66 compounds to various critical moulding applications since August 2012. The materials have been very well received with moulders being impressed by the quality of the nylon offered at such competitive pricing,” said Herman Botes of Rawmac. Zig Sheng will be exhibiting on a stand alongside the Rawmac booth. Rawmac: stand C33 Zig Sheng: stand B32 www.zigsheng.com

Relloy to show latest Erema ‘upcycling’ technology RELLOY will be showing some of the latest technology advances from its principal Erema, one of the leading global suppliers of systems for recycling of plastics – specifically with the new product COREMA®. This recycling system combines the benefits of recycling and compounding for the first time in one system and makes it possible to produce customised plastic compounds from inexpensive recycling raw material in a single processing step. On the one hand this means forward integration for the recycler in the direction of material production and, on the other, reverse integration for the compounder towards material procurement. This results in an enormous additional benefit which has increasing added value in line with the market trend.

The new COREMA® recycling system combines the beneﬁts of recycling and compounding for the ﬁrst time in one system (This equipment will not be on show)

Relloy: stand B23

ReichmansCapital

Wide variety of solutions from SABIC

ReichmansCapital, which offers asset finance and working capital funding to growing owner-managed businesses, will have a stand at Proplas. “We offer viable and realistic finance solutions to meet the funding requirements of business,” said a Reichmans spokesman. Reichmans has been in operation for over 35 years and built its reputation on partnering with its clients. Its services include: Asset finance Asset based lending International and local trade finance Debtor finance Special growth funding.

SABIC, one of the world’s leading producers of polyethylene and polypropylene as well as a major supplier of many other polymers will be participating at Propak Africa for the ﬁrst time. With over 60 global production facilities, the Saudi group works closely with many partners in research and academic institutions and converters all over the world to develop ever higher value products that help the world’s manufacturers make things better, faster, lighter – and in more environmentally-friendly ways. The following represent some of the products that customers can expect to see during Propak Africa 2013: PP 5707N (Stiffpact) SABIC mMultimodal HDPE blown ﬁlm

Reichmans: stand G10 36 FEBRUARY / MARCH 2013

HDPE for caps and closures PP 6711K random co-polymer for thinwall applications with high clarity PET woven tape fabric (developed in collaboration with Starlinger) several LLDPE grades PET grades used by our customers to make injection moulded food and drinks containers polystyrene grades used in packaging insulation. SABIC: stand D24

- passionate about the plastic industry. Visit us as PROPAK 2013 Hall 5 Stand C20

ty t o G

Injection Moulding Machine

Servo Klockner

Rebuild

VICTOR MACHINERY

Tel: +27 11 824 3103 - Fax: +27 11 824 6018 email: sales@sescc.co.za - www.sescc.co.za Unit 1, Davidson Place, Wadeville, 1428

INDUSTRY NEWS

Sheet Plastic’s slip sheets, boxes in corrugated PP Sheet Plastic will be exhibiting its range of slip sheets and boxes made from corrugated PP, aimed at protecting products during transportation and ideally used for the food, beverage, metal and glass transporting industries – but not limited to those industries. The slip sheets and boxes can be cleaned and washed to be re-used and are hence longer lasting and cost saving ... and can ultimately be recycled too. The slip sheets have rounded corners and are sealed, making them safer to handle as well as water resistant; the hollow core corrugated sheet is lighter and, being water resistant, avoids one of the problems with conventional cardboard, of becoming saturated with water or other liquids and deforming. Both the boxes and slip sheets can be made to customer requirements, in customer colours; customer speciﬁcations and details can be printed on. Various sheet thickness are available. Multi-trip cartons – The boxes and slip sheets from Sheet Plastics of Bloem are made from PP and are reliable, reusable and recyclable

Sheet Plastic: stand D28

Major range of injection machines on SES stand S.E.S. will show a wide range of machinery. In the injection moulding area, where SES (Seidel Electronic Systems) will show Electron 155 T, Omega 150Servo, Magna T Toggle, HDX168, HDJS168 and SKR25 injection moulding machine systems – possibly one of the most comprehensive range of injection machines ever shown by a single supplier

at SA’s premier show. Besides that, MP 70T extrusion blow and IBM 45 injection-stretch blow moulding machines will also be on show. In combination with SES’s technical team, principals from Ferromatik Milacron, Haida and AIBIM will be present on the stand. A full rebuild SKR with the integrated B&R system will be available for

perusal. Various ancillaries will be integrated onto the machines on display as well as a full function robot. SABIC: stand C20

Perspective of possibilities from Plastichem WHEN it comes to material selection for new projects and designs, Plastichem offers an invaluable perspective of possibilities. The company’s comprehensive range of polymers span from general styrene grades to complex PETG copolymers, better known as the ‘glass polymer’, to active packaging solutions like iron-based oxygen scavengers. Not only will Plastichem be highlighting packaging solutions that helped Europe reduce GHG emissions by 42.9 million tonnes, but you can also learn more about new polycarbonate LED lens applications that offer a 50% weight-reduction, an imperative for the automotive industry. Plastichem: stand D3

www.propakafrica.co.za

Specialised one-day events for Snax, IML, dairy & ice cream sectors VDS Media is launching three new industry events that will run in conjunction with Propak: Tuesday 12 March: SNAX Tech Africa provides an overview and insight into current market trends, opportunities and challenges in the market place, while providing valuable insight into the overall market, value chain and business impact and dynamics. Technical developments related to packaging and equipment technologies will be complemented by dedicated presentations about end uses and nutritional consumption. This event pulls together experts in their respective disciplines and addresses key topics for companies across the entire snacks value chain.

Wednesday 13 March: IML Tech Africa The ﬁrst African in-mould labeling and decorating conference, IML Tech Africa is the only African platform entirely devoted to IML and decorating, its technology and the African market. The one-day event provides an industry update, an insight into the current market trends, technology developments, an understanding of the added value of inmould labeled packaging and products. IML Africa 2013 engages experts from various specialities and addresses today’s key topics across the entire in-mould value chain. Thursday 14 March: Dairy & Ice Cream Tech Africa is the ﬁrst African related conference entirely devoted to the development and growth in the dairy and ice cream

industry. Developments in the industry’s value chain, encompassing various product assortments, design elements; manufacturing, packaging, machinery and end usage will be highlighted. It will also look at detailed insights into current market trends. The aim of the discussion will highlight opportunities and challenges in the dairy and ice-cream environment. The content that VDS Media will present will provide delegates with valuable industry and value chain insight and help identify unique business dynamics. Sporadic technical developments relating to packaging and distinctive equipment technology changes have brought huge transformation to the industry. Nutritional consumption and end product uses will be will be complemented by dedicated presentations.

38 FEBRUARY / MARCH 2013 • The conferences will run at Nasrec from 09.00 to 15.30. The events will be opened by a market insight study and will unfold to develop discussions surrounding the South African market.

where quality is action

A-PET

OBITUARIES APPOINTMENTS Jo Fitzell PLASTICS|SA’S regional training manager for the Western Cape lost his battle against cancer on 16 December. Born and raised in Potchefstroom, Jo was the youngest of four children. His love for life, infectious sense of humour and caring nature made Jo a much loved and respected husband, father and colleague. According to Sonja Fitzell, his wife of 22 years, Jo was diagnosed with prostate cancer in 1999, which was treated successfully. Sadly, however, he was diagnosed with pancreatic cancer 12 years later in October 2011. Jo lived for his family and friends and had a true passion for his job. “This passion drove Jo to get up each morning and drive to the ofﬁce, despite the fact that he was sick and often tired and a lot of pain. “Jo was not just doing a job to provide for his family. He was passionate about it,” Sonja said. The condolences of the entire plastics industry goes out to Sonja, and their children Duan, Sune, Nick and wife Christelle.

Bob Jones PASSED away in the comfort of his home and surrounded by his family on 17 November. Bob was a well-known icon in the packaging industry and will be missed by all who knew him. Steven Broekhuysen, CEO of Colpak, said: “Bob was an exceptional person who played a huge role in changing Colpak into the well-respected company that it is today, built on a foundation of integrity, honesty, service and quality. Wherever Bob went he built strong relationships and good friends. These relationships lasted through the decades. Bob recruited me into Colpak and shared a great deal of his knowledge and experience with me over the seven years that we have known each other. I will forever be indebted to him for all that he has shared with me. An exceptional person has passed on and his absence will be felt for a long time to come. We will honour him by building on the foundation that he laid and living by the same principles that he brought to the company.”

Andrew Bannatyne has been appointed head of the Rubber Division at Plastichem. Having been with Plastichem for over a decade, he now takes over the responsibility as business unit manager of the group’s Elastomers and Rubber Chemicals operation. Andrew began his career at Bayer in 1988 as a salesman for Bayer’s Rubber Division in Cape Town. Selling into the industrial, cable and adhesive industry, he achieved considerable success during his seven years with the company. He joined Plastichem in April 2001 as regional portfolio manager for the Cape region. Andrew’s astute business skills have served him well over the years, and no doubt he will continue this success story in his new responsibilities. He will continue to service his existing customers in the Cape region. Anton Nel has joined the SES team. Anton started his career in the plastics industry in 1995 at a German owned company where he was employed to manage their polycarbonate extrusion section. Subsequently, Anton completed his training in advanced setting, production planning and control and was plant manager when the company terminated all operations. Anton also spent four years in the raw material industry and has good knowledge about all aspects of processing, including injection moulding, blow moulding, extrusion and raw materials. Bright Rwodzi joined Goodyear Engineered Products Veyance Technologies as chief compounder. Bright was born In Zimbabwe and in 1997 started working for Dunlop Tyres in Bulawayo as a student attaché during his last year at university. He graduated with a BSc Honours in Applied Chemistry and since leaving university has also received qualiﬁcations in education, a certiﬁcate in quality assurance, management and control from the London City and Guilds Institute. He joined General Belting in 2002 and was technical and QA manager until he crossed the Limpopo in 2008 to take up the position of quality and technical manager at Dunlop Belting Products in Benoni. While he was in Zimbabwe and since moving to South Africa he been an active member of

the IOM³, serving on both committees. Paul Ferreira is the latest addition to the Cabletech sales team. Paul joined the company in September. Pictured here, Paul is opening up the first consignment stock order received from Cabletech’s new ancillary supplier, Shini in China, and the excitement is clear! Paul has become known in the industry as ‘Mr Shini’ and has achieved tremendous success over the years. Another new addition to the Cabletech team is Kelly Govender as Warehouse and Spares Manager. Kelly is also well known throughout the industry as ‘the guy that can source anything’. Chris Oberem joined Mouldplas in October to partner with Bryan Webb and Keith Reading, primarily heading up the sales and implementation of the Wittmann-Battenfeld range of equipment as well as Mouldplas’s new range of thermoformers from the Turkish Group, Yenniyurt and conveyor systems from Virginio Nastri. Chris has spent nearly 18 years in the plastics industry and began his career in Germany with an international plastics machinery manufacturer and brings with him a wealth of knowledge on plastics processing for the benefit of Mouldplas’s customers. Deon White joined Mouldplas in November to partner with Bryan Webb Keith Reading and Chris Oberem, primarily heading up the sales and implementation of the General Extrusion Technology (GET) range of coextrusion blown and cast film lines with systems up to 9 layers. Deon will specilaise in the sale of the company’s products based around flexible film and will include laboratory equipment, edge trim solutions, recycling systems from MUNCHY as well as a wide range of ancillaries such as air shafts and web guides, lamination and printing equipment.

Hestico ‘green’ competition winner MACHINE supplier Hestico is a keen supporter of the environmental programmes run by PlasticsSA and presented a fund-raising competition at Afrimold last year to raise funds for the ‘green’ causes being pursued. Entrants had to buy tickets and, three days after the show, a lucky draw was held with the winner being Anton Buchner of Plastomark, who received the prize – an iPad2 – from Hestico MD Juanita Stiehler-Brits. Proceeds from the ticket sales went to PlasticsSA, to be used to fund one of its environmental programmes. 40 FEBRUARY / MARCH 2013

PEOPLE

INTERVIEW INTERVIEW: KEITH WATKINS

Keith Watkins retires KEITH Watkins, who managed Thermopac’s entry to the Astrapak stable while he was running the Cape Town thermoforming business and who went on to become one of the Astra group’s top directors, retired from ‘active duty’ at the end of last year. Keith was one of the most debonair individuals in the industry, and widely liked, but he also faced some tough challenges during his tenure as director of Astrapak’s coastal division. How did you get involved in the plastics industry? I was recruited from business school by Consol’s Glass Division as a marketing manager and later transferred to Consol Plastics to build and manage their Durban plant. Then, after a few years of absence from the packaging industry, first at PG Glass and then as a shareholder and MD of Bakker & Steyger and Gomma Gomma, Ray CreweBrown hired me to run Emcape, as Thermopac was then known, in Cape Town. How did Thermopac become part of Astrapak group? (Thermopac was the first business to join the group.) Emcape and Thermopak were bought from Kohler Plastics and Consol respectively and merged into Thermopac to become the first

of many companies comprising Astrapak Ltd. Thermopac developed to become the leader in its markets and a top performing company in Astrapak. You have been involved in the management of the Astra group since: what were some of the highlights for you? A milestone for Thermopac was the commissioning of the first PET sheet extruder in Africa, which effectively rendered thermoformed PVC packaging obsolete and launched it ahead of the competition. The heydays in Astrapak were when we were a decentralised group of fanatically hands-on owner-managers growing the core companies passionately. Astrapak has been subjected to quite a lot of criticism by the financial press, possibly because dividends in recent years have dipped from the levels achieved during the group’s early years: how do you believe the group strategy could have varied to achieve better financial results? I am confident that the new CEO will implement the strategic changes required to restore Astrapak’s leadership position given his track record in the industry. Astrapak owns some of the finest companies in the plastic

packaging industry Gone biking and has very – Watkins plan Keith competent more time tras to spend and heading velling general managers. out on his Beemer Radical change is however required to catalyse those into the performance that they are capable of. What in your view would be the most effective strategy, in general, for medium-sized converting businesses to pursue in South Africa for the near future (up to 2020)? Pricing pressure ensures that only the lowest cost manufacturers will produce acceptable returns. Therefore modern plant and best practices on the shopfloor are the keys to successful manufacturing. The results are manifest in the ability to satisfy customers continually and acquire new business. Respecting your customers and avoiding the arrogance of bureaucracy will ensure that the emphasis is correctly placed within operations. It starts with the motivation and training of shopfloor employees who create the primary value. Higher level strategies are impotent until the shop floor is world class. FEBRUARY / MARCH 2013 41

TURKISH POLYMER INDUSTRY

RESILIENT AND GROWING

Established domestic market provides volume, economy of scale to allow marketing ﬂexibility for exports

The Turkish Pavil ion

at ArabPlast 2013

Ortaköy Mosque in Istanbul, Turkey, is located in the middle of the Bosporus, on the coast of Ortaköy District in Beşiktaş County

The Turkish plastics industry is primarily made up of converters. With 6.7 million tons IS Turkey Europe? Or is it Asia, or of polymer being processed each year it the Middle East? Geographically it ranks as the third largest plastics industry is the bridge between Europe and in Europe, behind Germany and Italy but ahead of France, Spain and the UK. Asia – in fact Istanbul is on both Around 70% of the polymer processed continents! Europe was strongly is used in Turkey and so, unlike countries influenced by Turkey during the strongly dependent on sales in the EuroOttoman period when much of pean Union, the industry has continued to grow even during the economic crisis. While Eastern Europe was part of the Empire, as was the North African the domestic market, measured in terms of average per capita plastics consumption is coast of Egypt, Libya and Algeria, relatively high at 65kg/person (compared present day Lebanon, Syria, Jor- to 75kg/person in Europe, 90kg/person in dan, Kuwait, Iraq and even parts North America and 25kg/person in South Africa), increases in the standard of living of Saudi Arabia and Yemen. Looking at Turkey’s large plastics industry and a relatively young population means that the domestic market is capable of it is easy to ask the same question: is it further growth. more like the industry in Europe or the Turkey is also well positioned to grow its Middle East? Unlike most of the Middle East plastics industry it is not dominated by large exports from the already large $4.6 billion achieved in 2012. Some of these exports polymer plants producing raw materials for are to Europe: Germany, the UK, France export – in fact more than 85% of the polyand Italy are all in the top ten markets, but mer processed in Turkey is imported. so are Middle East countries such as Iraq The main polymer producer in Turkey, (the biggest export customer for plastic Petkim, produces some PE, PP and PVC and there are also smaller producers of PS converters) as well as Russia and other and PET. While Turkey does not have signif- fast growing Central Asian countries like icant oil or gas reserves, it does lie between Azerbaijan. The largest industry sector is packaging, the gas-rich Caspian Sea region (where 47% of the world’s natural gas reserves are including BOPP, stretch- and shrink films, woven bags and food packaging. Growth in located) and an energy-importing Europe packaging is driven by increased consumer looking to reduce its dependence on Rusdemand; an expectation that goods are sian oil and gas. packaged to EU standards, as well as supThere are a number of pipelines linkporting exports from the large Turkish agriing Iran and Iraq with Turkey and others, cultural sector (which is also a big market for including the 3900 km Nabucco pipeline greenhouse and other agricultural film). linking Azerbaijan, Iraq and Turkmenistan Products for the building and construction to Austria, are planned. It is likely that the industries, including pipes as well as window petrochemical industry will grow based on and door profiles, account for almost 25% of the increased availability of raw materials plastics converted in Turkey. There is a large once these pipelines are completed.

FEATURE

BY DR NIALL MARSHALL

42 FEBRUARY / MARCH 2013

textiles market and the largest producer of polyester fibres and filaments in Europe and the Middle East is SASA. One of the most interesting features of the Turkish plastics industry is the number of companies: more than 6 000 employing 200 000 people (in a country of 74 million people) and creating almost 20 000 new jobs every year (even in 2011). Most of these companies are considered to be SME (less than 200 employees) and the level of competition between so many converters has forced them to be efficient to the level of being able to compete in export markets, including Germany. This is perhaps the secret of its resilience and growth: an established domestic market that provides the volume and economy of scale to allow for the marketing flexibility for exports. Perhaps it doesn’t matter whether Turkey is considered Europe or the Middle East. It is as much a geographical bridge between the regions as it is a link between the established ‘old world’ economies and cultures of Europe and the developing ‘new world’ economies of the Middle East and Central Asia. Maybe it will again influence these regions as it did for hundreds of years. 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

Be on target Injection moulding

Extrusion

Pulverisers Granulation Systems

Jingmi Ancillaryâ&#x20AC;&#x2122;s

Gravimetric Systems

Extrusion Laboratory Equipment

Visit us PROPAK Hall 5 Stand B6

Mixing & Blending Blow Moulding

and Win with Cabletech

Huayan PET Systems Pelletising Systems

Purging Compound Barrel & Screws

For further information contact: Pierre Jurgens: +27 (0) 83 276 1978 10 Staal Street Kya Sands Randburg

TEL: +27 (0) 11 704 0824

FAX: +27 (0) 11 462 2108

:(3,: :,9=0*, :<7769; :<**,:: :05*, E-MAIL: info@cabletech.co.za

WEBSITE: wwww.cabletech.co.za

EQUIPMENT

New hot runner technology

improves outputs New type of tip differs in design, proven to reduce heat loss from tip into mould THE growth in hot runner sales this last decade has been exceptional. This is a reflection of improved hot runner technology and temperature control, as well as a better understanding of melt-flow analysis and the benefits that hot runners bring to production. Having said that, hot runners are not without their challenges! A major problem of traditional hot runner nozzles is their inability to maintain the correct temperature at the gate. Nozzle construction and the thermo conductivity of the materials used, result in much of the heat generated at the tip being lost into the mould plate itself, rather than it being retained in the tip. This results in ‘freezing’ of the gate area and loss of production time while the blockage is cleared. To compensate and prevent gate blockages, many machine setters tend to over compensate the heat being delivered at the gate by running nozzles at temperatures far in excess of those recommended

by the material manufacturers. The result of this overheating is longer cycle times and degradation of sensitive materials, inconsistent quality, drooling or stringing at the gate, and many other time consuming and costly problems which often necessitate mould maintenance. There is, however, a solution to this problem. After much research and many trials, DME offer a new type of tip which differs in design and is proven to reduce the heat loss from the tip into the mould. The new DME V-Range technology is based on using materials of varying heat conductivity to ‘direct and contain’ the heat in the tip. Essentially, the heat conductive nozzle body is made up of a specially coated nozzle shaft, into which is screwed a highly conductive alloy tip. Both are encased in the heater coil. Heat from the coil and nozzle body is directed straight to the tip. This heat is then contained by an insulating nut made of low conductivity material. This acts as a

V-Range: • Clean gate/ vestige • Less heat transferred to plastic part

thermal barrier preventing excessive heat dissipation into the mould cavity plate. Minimal heat loss into the mould means that the product can be properly cooled in the gate area, resulting in the moulding of a superior product with a neater injection point. As an option, high wear resistant tips are available for abrasive materials, as well as front loading heaters which allow for heater changes from the mould parting line without having to disassemble the mould. To assist potential users to ‘trial’ this new technology, DME are currently manufacturing ‘custom’ V-range nozzles which can then be retroﬁtted into existing hot runner systems to run alongside existing units for comparative purposes. FOR MORE INFORMATION ON THESE AND ALL OTHER HOT RUNNER NEEDS, CONTACT MOULD & DIE SOLUTIONS ON 021 555 2701

Others: • Potential stringing at gate/vestige • More heat transferred to plastic part

A conventional nozzle loses heat into the mould

Coated shaft

Nozzle tip

44 FEBRUARY / MARCH 2013

Nozzle nut

Assembled nozzle

Direct contact between the heater and the nozzle tip provides greatly improved temperature control: • lower melt temperatures • distinctly lower energy requirements • superior moulding quality • shorter cycle time • improved dimensional accuracy • reduced stress on sensitive material • less downtime

www.m-d-s.co.za

www.dmeeu.com

Beck’s new production hall with injection moulding machines from Wittmann Battenfeld

Quick, reliable and high-quality

EQUIPMENT

Flexibility and diversity in manufacturing products BECK Kunststofftechnik, based in Vellmar near Kassel/Germany, supplies its customers from many different industries quickly and reliably with high-quality plastic parts. They are manufactured exclusively on injection moulding machines from Wittmann Battenfeld. Established in 1976, the family-owned company follows a concept of flexibility and diversity in manufacturing its products. At Beck, everything comes from a single source, from making the offer, including product development and mould-making, right up to the finished plastic part. Beck offers a wide range of products to its customers, from a great variety of industries such as the electrical, electronic and automotive industries, or manufacturers of transport equipment, household goods and advertising materials. Beck designs and builds the required moulds in-house to customers’ specifications. This enables the moulds to be produced within only a few weeks. Quick alterations to existing moulds are also The mould to produce plastic parts for playground equipment manufactured by Beck

possible thanks to in-house production. The range of moulds includes 2-component moulds, moulds with collapsing cores, moulds with several slides moving one above the other, or split moulds. More than a thousand moulds are currently in use. Some 300 to 500 tons of plastic materials are processed each year. About 100 different materials are injection-moulded at Beck. The finished parts are also further processed in-house where necessary. In addition to assembling individual components and mounting more complex assemblies, Beck also offers screen printing, pad printing, customized packaging of any kind, as well as pressing in gaskets and ball bearings. The company keeps its own truck for quick delivery of the finished parts. The company’s vital success factors, besides flexibility and diversity, are speed and high quality standards. Its market is Germany, with some of its customers also operating internationally to a certain extent. One example of this is Expresso, The finished parts are packed according to the customer’s specifications

Plastic parts for luggage trolleys from Expresso

a market leader in transport equipment, whose luggage trolleys can be found at airports and train stations around the world. For injection moulding, Beck relies 100% on Wittmann Battenfeld. On a 2,500 m² production ﬂoor, Beck now has 29 injection moulding machines installed, all from Wittmann Battenfeld. The injection moulding machines currently installed at Beck range from 25 to 500 tons in clamping force. The machinery consists mainly of toggle machines from the TM series. In August 2012, two 55ton machines from the EcoPower series were delivered. www.beck-formenbau.de www.wittmann-group.com

46 FEBRUARY / MARCH 2013

â&#x20AC;&#x153;The empires of the future are the empires of the mind.â&#x20AC;? Winston Churchill

EQUIPMENT

Delta Tooling & VISI work

hand-in-hand Perfectly mirrors human movements THE VISI suite of CADCAM applications from Vero Software has been instrumental in helping a precision engineering company develop the world’s most advanced commercially available myoelectric prosthetic hand currently on the market. Delta Tooling (Horsham) Ltd was approached some two years ago by prosthetics specialists RSLSteeper to assist in the manufacture of the bebionic3 prosthetic hand, which is transforming the lives of amputees worldwide, helping them to regain independence and control in their everyday lives The bebionic3 uses leading-edge technology to trigger one of 14 programmed grips, perfectly mirroring human movements. The bebionic3 hand is designed so its users can carry out everyday tasks such as using a computer keyboard, tying shoelaces and chopping vegetables. Operating from Billingshurst in West Sussex, Delta Tooling now manufacture ﬁve parts for the hand, including the aluminium knuckle, the plastic sub-section it connects to and a complex thumb bracket that allows the opposable thumb to rotate and move backwards and forwards. RSLSteeper originally approached

Delta Tooling’s directors Gary Childs and Luke Tetlow with an all-plastic moulded product which had to be partly machined when removed from the mould tool. “The initial concept of casting or moulding the components, followed by ﬁnish machining operations before assembly and testing, gradually evolved into fully machined parts to improve quality and maintain consistency,” says Gary Childs. “Maximising our use of VISI Machining, we developed strategies that not only machined the parts from solid billets, but produced them in highly competitive times.”

The bebionic3 uses leading-edge technology to trigger one of 14 programmed grips, perfectly mirroring human movements. The bebionic3 hand is designed so its users can carry out everyday tasks such as using a computer keyboard, tying shoelaces and chopping vegetables 48 FEBRUARY / MARCH 2013

5-axis machining is perfect for manufacturing the bebionic3 products, and VISI provides Delta Tooling’s operators with a productive solution for preparing the geometry for manufacture and creating the highly efﬁcient toolpaths required to manage the increasing complexity of the components involved. The bebionic3 was unveiled worldwide in the United States in September, and subsequently introduced to the United Kingdom at a London launch in November.

www.visicadcam.com www.verosoftware.com www.deltatooling.co.uk

The Engel duo 80000H/80000H/5500 has the biggest and heaviest mould clamping platens – each weighing 95 tons – Engel has ever built; space between the tiebars is 2580mm in width and 2800mm in height, which allows the 112 ton mould to be inserted and removed without problems

Biggest Engel machine yet

EQUIPMENT

5500-ton machine ENGEL recently supplied the largest injection machine it has ever manufactured, a 5500-ton clamp force unit that is being used by Sulo group to mould 4-wheel waste bins. With edge lengths of 3.5 metres and weighing 95 tons each, the mould clamping platens of the Engel duo 80000H/80000H/5500 injection moulding machine are the biggest and heaviest Engel has ever built. And the model set another record too: there is no other machine of this size on the market which achieves comparable energy efﬁciency. Sulo Umwelttechnik is among the world’s leading suppliers of high-quality rubbish and recycling collection containers. It launched the ﬁrst plastic four-wheel rubbish containers onto the market 40 years ago, in that case constructed in steel. The vast majority of steel containers have since been replaced by plastic successors. By investing in this new largescale machine, Sulo has increased the capacity at its Herford site and is now able to produce four-wheel containers with capacities of 660, 770, and 1100 litres. The largest rubbish containers are 1200mm x 1000mm x 1000mm. The formidable size of the machine before its departure from Engel’s large-scale machine factory at St Valentin, Austria

The new Engel duo was formally unveiled at Sulo’s premises and included celebrations to mark the 40th anniversary of the development of Sulo’s ﬁrst bulk rubbish container, here we see Christopher Vitz, MD of Engel Deutschland, Christian Pum, sales director at Engel Austria, and Dr Eric Bernhard, CEO of Sulo group

The space between the large machine’s tiebars is 2580mm in width and 2800mm in height, and allows its mould, which weighs 112 tons, to be inserted and removed without any problems. Two barrier screws with a diameter of 215mm and a length/diameter ratio of 24:1 feed in the HDPE material, while the narrow design of the injection units means the nozzles can be 2050mm apart. The injection pressure is 2100 bar.

level of energy efficiency: it’s been fitted with the Engel ‘ecodrive’ servo-hydraulic system. During cooling phases, for example, the idling and flushing energy consumed by conventional hydraulic systems is saved completely. This lowers Sulo’s annual electricity consumption by more than a million kWh, the equivalent to the annual consumption of 220 fourperson households. www.sulo.com

Lost energy reduced drastically The new machine also achieves a high 50 FEBRUARY / MARCH 2013

www.engelglobal.com

SOUTH AFRICA Polymers Division

O U R W I N N I N G F O R M U L A S E T S U S A PA RT Carst & Walker has developed sustainable partnerships with leading international suppliers and valued customers for more than 70

Rubber and Plastic industries. Within the Polymers Division, the following business units provide the customer with the ultimate polymers solution:

ELASTOMERS

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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

Cape Town: Tel: +2721 506 4560 Fax: +2721 506 4561

sales support

Port Elizabeth: Kathy Garde Tel: +2741 397 3600 Fax: +2741 397 3601

service excellence

A HOBART COMPANY

technical expertise

leading international manufacturers

The recoSTAR universal 165 for hard-to-grind and voluminous plastic waste

Two ‘big brothers’ for Starlinger’s well-proven recoSTAR family

EQUIPMENT

recoSTAR PET 330: More than 27,000 tons per year of rPET for B2B applications STARLINGER recycling technology has increased line capacities: recoSTAR PET 330 for post-consumer PET recycling, and recoSTAR universal 165 with the focus on hard-to-grind material and voluminous waste with specific processing requirements. For some years now the capacity per installation required on the market has been continuously rising, especially in countries with large populations and/or high collection rates. Washing line producers have already responded to this increase with higher throughput/output rates; now it is time for the extrusion lines to draw level with them. Larger lines are also more efficient because the operating expenses are comparatively lower and they deliver a higher ROI. Starlinger recycling technology introduced the HC (high capacity) feature in 2006 as a first step towards capacity increase and gained 25% more output without changing the extruder diameter. The aim was to develop a recycling line that can produce more than 25,000 tons of bottle grade rPET per year, primarily rPET pellets with virgin-like characteristics. Further requirements included FIFO for excellent product properties and uniform The recoSTAR PET 330 operates with 2 parallel 165 mm extruders

treatment of flakes and pellets, full automatisation and easy maintenance during production, process control and parameter documentation for traceability, and energy saving production. For the recoSTAR PET 330, two 165 mm single-screw extruders are mounted parallel on a main frame, while the upstream and downstream equipment is adequately sized so that only one predrying unit, filter and pelletizer are needed for the two extruders – which, in turn, helps to keep the cost of the entire line down. The advantage of using two single-screw extruders instead of one large extruder is the low technology and process risk. 327,850 ton installed PET recycling capacity per year The first recoSTAR PET lines were designed to produce an average output of around 5,000 t of rPET per year mainly for food contact packaging. Between 2004 and 2010 Starlinger recycling technology installed 22 PET recycling lines with an overall rPET capacity of more than 175,200 t/y (approx. 8,000 t/y per line). The 11 new installations sold in 2011 and 2012 alone will have nearly the same capacity – namely 152,650 t/y (almost 22,000 t/y per line). For recycling pre-shredded and washed material (post-industrial or post-consumer), the market offers a great variety of large recycling units. For plastic waste that is voluminous, hard-to-grind and with specific processing requirements due to type and amount of contamination, however, the available solutions are limited or nonexistent at all. Starlinger has installed over 100 52 FEBRUARY / MARCH 2013

The recoSTAR PET 330 iV+ during the Open House of Starlinger recycling technology in Weissenbach in June 2012

recoSTAR universal lines for a variety of applications in the past years. The aim was to develop a recycling line with a production capacity of up to 10,000 tons/ year suitable for processing a wide scope of thermoplasts in almost all conditions. In addition it should be possible to add e.g. calcium carbonate powder for compounding, or PET bottle flakes for improving the viscosity of PES filaments. While the recoSTAR universal 165 is able to handle all sorts of waste difficult to process, it maintains the core advantages of the recoSTAR universal system: flexible modular design, operator and maintenance friendliness, efficient material preparation, feeding control for consistency and process stability, and constant high pellet quality. • STARLINGER RECYCLING IS REPRESENTED IN SOUTH AFRICA BY MARITIME MARKETING. www.marimark.co.za www.recycling.starlinger.com

Visit us at Propak 2013 â&#x20AC;&#x201C; Stand 5 B23

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

(PHOTOS: ILLIG)

Dieda brand system components on the shelf in the do-it-yourself store: Many components are offered in skin packs, especially from product range ‘hand rails and guarding systems’ ( right)

Skin packs offer

Illig SB 74e-4 skin packaging line working at Dieda Systembau: The parts to be packed are positioned on a carrier board on the 4m feeding device and automatically transported to the thermoforming station (top). After sealing, packs ready for sale are cut by the longitudinal and cross cutter (bottom left) and discharged from the packaging line (bottom right)

eye-catching presentation

EQUIPMENT

Ideal pack, especially for small parts MORE than 200,000 packs are manufactured annually by Dieda Systembau GmbH & Co. KG, the Swabian specialist for do-it-yourself system components, on their new Illig SB 74e-4 skin packaging line. About 85 different products are manufactured ready for sale. They are ﬁxed on printed cardboard by a transparent foil, cut to size and equipped with a hanging hole on the head side. From Egenhausen, the company location in Baden-Württemberg, the skin packs are distributed to about 1,500 do-it-yourself stores all over Europe where they are available for do-it-yourselfers as a range of system components for stairs, guard rails and balconies to be used for new buildings, modiﬁcations or renovation activities. A cost comparison reveals that skin packs are frequently cheaper than comparable cardboard packs. Technically, no tools are required thus no follow-up investments will have to be made which

is a major advantage of the skin pack. The skin packaging line, including automatic feeding device, thermoformer, follow-up longitudinal and cross cutter as well as discharge conveyor, is of linear conﬁguration and adjusted to Dieda’s sequence of work. The total area of the printed carrier card for the components to be packed is used several times, i.e. 12-up or 18-up, subject to the content to be packed. Subsequently, the cardboard blanks loaded with products are automatically transported into the skin packaging machine. There, the heated material is safely bonded with the cardboard by means of high suction capacity. Rework-free end packs are manufactured by employing the follow-up longitudinal and cross cutter. A highly transparent foil is used for sealing requiring a low sealing temperature and featuring high strength of sealing seams and very high puncture resistance at the same time.

Variable machine technology The Illig SB 74e-4 skin packaging line is equipped with a max. forming area of 505 mm x 775 mm. Essential features of equipment level 74e-4, as used by Dieda, are the integrated longitudinal and cross cutting system with hole punch press. Control units located on longitudinal and cross cutter prevent damage to the knives by automatic machine stop. The longitudinal cutting knives are mounted on a carrier rail and can be set to the required grid dimension outside the machine. Quick-change technology allows exchange of the complete unit. The positions of cross cutter, working with a cutting accuracy of ± 0.5 mm, and hole punch press can be digitally set, stored and recalled, if required. • ILLIG IS REPRESENTED IN SA BY HESTICO www.dieda.de

Maag Automatik unveils new Chinese facility TO further increase its footprint in the far-east and re-state its interest in China and the Asia-Paciﬁc region, maag automatik has opened a brand new facility in Shanghai, with its parent company, the Dover Corporation. The 11,000 m2 building will help maag’s customers optimize their own operations with services, including localized technical expertise, improved after-sales support and customer service in an ISO 9001-certiﬁed facility, shared with the company’s new owner and its subsidiaries. The state-of-the-art complex includes a 30-seat room to provide education and training opportunities for end-users and distributors as well as a product showroom where visitors will be able to observe how maag’s locally-made products are manufactured and operated. • Maag is represented in SA by Joesten International

www.maag.com

54 FEBRUARY / MARCH 2013

SERVO DRIVEN INJECTION MOULDING MACHINES

from 90 Ton

to 2800 Ton

• • • • • • • •

90 – 320 Ton are normally EX-STOCK European B&R closed loop control system 36% Energy saving over Variable Displacement Pump Machines Piston Driven System has energy and mechanical advantages over gear pump and screw pump servo systems Reaction time of servo system is 40ms from rest to 1500rpm 0.3% weight deviation (82g product moulded on 190SE) ECO friendly Oil Filtration system Extremely competitive pricing

Tel: 011 762-5231 • Fax: 011 762 5228 • Mobile: 082 465 9491 • steve@edmshop.co.za • www.edmshop.co.za

EQUIPMENT

Nissan water outlet made in Solvay PPA eliminates party lines THE high elongation possible with Amodel® polyphthalamide (PPA) from Solvay Specialty Polymers has enabled Nissan Motor Company to eliminate the parting line commonly occurring in the injection moulding of a complex water pump. The innovative automotive cooling part The main function of the water outlet is to act as a manifold for the cooling system. It features 10 seamless barb ports that feed coolant to and from the transmission cooler, throttle cooler, heater core, oil cooler and provides coolant to the radiator

is manufactured by MPC Inc, an injection moulder based in Walworth, Wisconsin, USA. MPC is able to produce the part with a 450 gram weight reduction versus metal. Use of the Amodel® PPA enables MPC to produce the without a parting line on the barb of the 10 outlet and inlet tubes. In typical plastic parts, the parting line could be sharp and create a cut during installation, resulting in a coolant leak path. OEMs specify no parting line in the barbed area as a result. Solvay’s Amodel® AS-1933 has superior elongation at the recommended mould temperature of 135°C compared to other PPAs and polyphenylene sulﬁde (PPS). The material’s elongation allows injection moulders to eject the parts from the mould without producing a parting line in the barbed area, unlike conventional injection moulding. Seamless barb joints are made possible through precision timing of multiple valve gates and multiple slide actions to properly form this complex part in one piece. AS grades of Amodel® PPA have been successfully used by many auto OEMs in numerous heating and cooling components.

Among the key design guidelines and recommendations: the maximum undercut ratio should be around 8-9% and the ejection angle should be greater than 150 degrees. In case of outlets with a small diameter, it is possible to mould the undercut in the range of 12-13% with a special provision. The plastic water outlet eliminates the need for 18 machining operations and eliminates 20 potential leak paths. It achieves machined metal tolerance right out of the mould, without any secondary machining. Tooling for competitive cast aluminum parts should be replaced after about 100,000 cycles – which adds to the cost. In comparison, tooling for Amodel® PPA injection moulded parts will last the life of the Nissan engine programme. • SOLVAY SPECIALTY POLYMERS IS REPRESENTED BY SOLVAY POLYMERS & CHEMICALS SA OF PRETORIA.

www.mpc-inc.com www.solvayspecialtypolymers.com

ZSK used for production of conductive compounds Twin screw extruder for the production of conductive polymers Conductive carbon – The German material producer Delta Kunststoffe AG is now using a ZSK MEGAvolume PLUS twin-screw extruder from Coperion GmbH (formerly Werner & Pﬂeiderer) for the production of electrically conductive polymer compounds. The extruder serves to mix conductive carbon black into the melt. Polymers processed include PP, PD, PS and PA 6. Depending on the requirement – from antistatic to readily conductive polymers – the extruder, equipped with 76mm diameter screws, produces compounds with a carbon black content of between 15 and 40% w/w at an output rate of 1000-1,500 kg/hour.

56 FEBRUARY / MARCH 2013

www.coperion.com www.delta-kunststoffe.de

EQUIPMENT

Deceuninck, in Diksmuide, Belgium, a sustainable building products manufacturer has installed a new recycling line from equipment technology specialist Bühler, taking its annual recycling capacity up to 20,000 tons

Bühler’s optical sorting experts supplied and installed the complete sorting solution, including all equipment surrounding its ‘Sortex’ technology, at Deceuninck

Recycling PVC:

Bühler system allows sorting of 20,000 tpa Simply another source of raw materials for Belgian company EQUIPMENT technology specialist Bühler has coordinated and installed a turnkey optical sorting system for PVC for Deceuninck, a Belgian sustainable building products manufacturer. The system forms part of its new recycling line which Deceuninck started in October 2012 in Diksmuide, Belgium, taking its annual recycling capacity to 20,000 tons. With sales in more than 75 countries, as one of the top three European compounders and producers of PVC window systems and building products, Deceuninck recently acquired a PVC recycling line as part of its global strategic vision, ‘Building a Sustainable Home’. The line, which processes both post-industrial and post-consumer rigid PVC waste, is in-

stalled adjacent to the company’s existing state-of-the-art compounding factory. For Deceuninck, recycling is simply another source of raw materials. In order to meet its efﬁciency requirements, Deceuninck contacted Bühler in January 2012 to source the most appropriate sorting technology for the job. After initial consultation, Bühler’s optical sorting experts were able to supply and install the complete sorting solution, including all equipment surrounding its ‘Sortex’ technology. Bühler’s expert team worked with Deceuninck to undertake in-house trials and demonstrations to identify the most appropriate solution to meet the company’s needs. Bühler’s engineers then oversaw

the installation, including the commissioning of its Sortex Z+ bichromatic colour sorting machine and the required auxiliary equipment. Bühler’s optical sorting technology can sort two tons per hour of mixed PVC 50% white and 50% colour into groups. The sorted material can then be reused and transformed into new window systems and building products. • BÜHLER IS REPRESENTED IN SA BY BÜHLER SA, TEL: 011 801 3500

www.deceuninck.com www.buhlergroup.com

Smart choice for blow moulding machines Compact, fast SMART Machinery & Moulds of India has launched its smallest extrusion blow moulding machine in the world. Maximum use of floor space was the key force driving the need to develop compact extrusion blow moulding machines. Customers can gain higher productivity from the same floor space available with them – smaller footprint, faster cycles result in higher output. Smart Extrusion blow moulding machines have the smallest floor space used in the industry and are custom built to be suitable for various applications. The smallest blow moulding machine has a capacity from 5ml to 2 litres which can even be operated from very small space. The semi-automatic machine also helps to reduce manpower. Smart machines are compact, fast and energy efficient. Smart can also assist in reducing tooling costs without compromising quality. Their engineers have expertise in 2D/3D modeling, mould & tool design, holding experience, and fully supported by CAD/CAM technology, can work with the customer from concept to finished product. www.smartmmpl.com

58 FEBRUARY / MARCH 2013

THEN ...

Prof Carl Duisberg was MD of Farbenfabriken Bayer from 1912 to 1925. The planning, construction and development of the Leverkusen site is considered to be the most signiﬁcant milestone in his career

Bayer’s central scientiﬁc laboratory in Wuppertal, Elberfeld in 1891

150 years of Bayer:

MATERIALS

Success through innovation & change THE Bayer Group will be celebrating its In the area of high-performance 150th anniversary in 2013 with numerous materials, the polyurethanes for foams events around the world. Bayer discovered in the 1930s and the high“What started as a small but innovative performance polycarbonate (Makrolon™) dyestuffs factory in the Barmen district of that was patented in 1953 form the basis Wuppertal, is now a for an ever-expanding global enterprise with range of applications. The spirit of inventiveness more than 110,000 Today, highand the will to succeed form employees. In the performance the bridge spanning the past 150 years, Bayer materials from Bayer company’s history from its inventions have time MaterialScience origins 150 years ago and again helped make an important to today improve people’s contribution to quality of life. This conserving fossil great tradition is also our commitment to the resources. Polyurethanes, for example, future – entirely in line with our mission of are used to insulate buildings and thus Bayer: Science For A Better Life,” said CEO reduce the amount of energy used in Dr Marijn Dekkers. heating or cooling. Lightweight materials The Innovation Centre at RLE International worked with Bayer MaterialScience to develop fenders and trunk shells for a Rewaco trike. The moulded plastic parts produced by Multitec short ﬁbre spraying have a high-quality surface and brilliant gloss even without coating

NOW ... 60

Bayer products have become indispensable to our lives

help make cars lighter, thereby cutting their fuel consumption. It is thanks to the invention of aliphatic polyurethane coatings that assets can be preserved for longer than ever before. Modern coating systems can withstand both wind and weather and put a shine on cars, ships, rail vehicles and wind turbines. Pharmaceuticals research at Bayer HealthCare concentrates mainly on the ﬁelds of cardiology and hematology, oncology, women’s healthcare and diagnostic imaging. A further focal point of Bayer research is agriculture. Today, Bayer CropScience is a global leader in its ﬁeld. This success is based on innovations, not only chemical and biological crop protection products that offer sustainable solutions,

Various transparent, metallized and opaque coloured components made of Bayer’s Apec are used in the headlights of the Volkswagen Golf

but also high-quality seed. Added to this is a broad range of products and services for home and garden and forestry applications. On-going change and renewal An anniversary like this instantly calls to mind words such as tradition and continuity, according to Dekkers. However, Bayer can actually look back on 150 years of on-going change and renewal. The company was founded as ‘Friedr. Bayer et comp’ in August 1863 by businessman Friedrich Bayer and dyer Johann Friedrich Weskott in the Barmen district of Wuppertal. Bayer initially produced synthetic dyestuffs, but the range of products grew significantly over the years. In 1881, the company was made a joint stock corporation, ‘Farbenfabriken vorm Friedr Bayer & Co’ and developed into an international chemical company. In the course of expansion, Bayer relocated its headquarters to Leverkusen in 1912. Following the First World War, in 1925, the company became part of the IG Farbenindustrie AG conglomerate. It was re-established as an independent company named ‘Farbenfabriken Bayer AG’ in 1951. The pace of change picked up significantly following Bayer’s 125th anniversary in 1988. The company shifted its focus more towards its core activities, resulting in the sale of subsidiary Agfa in 1999. In 2005, Bayer then spun off significant parts of its traditional chemicals business under the name Lanxess. At the same time, the healthcare and agriculture businesses – referred to as the ‘life sciences’ – were systematically expanded, especially with the acquisitions of Aventis CropScience (2001) and Schering AG, Berlin, Germany (2006). www.bayer.com FEBRUARY / MARCH 2013 61

With the opening of the ﬁrst training workshop at the Leverkusen site in 1901, the foundations of vocational training at Bayer were laid

Bayer today produces a range of high-performance materials, including Makrolon polycarbonate, seen here in the Hyundai ‘i-mode’ Makrolon roof module

Another high-performance material produced today by Bayer is its range of polyurethanes. As part of a renovation project the tracks on the Zollamt Bridge in Vienna have been laid on sleepers made of a Baydur 60 grade reinforced with long glass ﬁbres produced by Sumika Bayer Urethane Co. Ltd., the Japanese polyurethane systems house in Bayer MaterialScience’s global BaySystems network

PHOTOS: BAYER

Otto Bayer conducting an experiment in 1952. Today, the polyurethane reaction process is one of the established methods of producing plastics. (Otto Bayer was not related in any way to the founder family)

MATERIALS

New silicone O-ring

Trelleborg and Boehringer Ingelheim microParts are now working on advancing product design

A leap forward for inhaler users WITH metered-dose inhalers, precision is paramount, in terms of both medication delivery and the technology involved in creating the product. A device from Boehringer Ingelheim is a leap forward on both scores. Anyone who’s ever taken medication with a conventional metered-dose inhaler will know how hard it is to inhale ﬁrmly and precisely enough to get the sudden spray down into the lungs. Many users take an extra dose or two, as they’re unsure if they took it quite right the ﬁrst time. But what if you could simply take a deep, relaxed breath and the medication would glide down into the lungs? The pharmaceutical company Boehringer Ingelheim has developed an inhaler, the Respimat®, which produces a gentle cloud, leaving plenty of time to breathe in and get the medication where it needs to be. The heart of the Respimat is the uniblock nozzle system. Fine grooves are etched into a wafer of silicon using the same technology as in the semiconductor industry, and when the liquid is forced

through, two ﬁne jets are produced that dissolve into mist when they meet. By turning the base of the inhaler, liquid is drawn from the cartridge through a capillary tube into a dosing chamber. Turning the base also primes a spring, which is trigger-released to force the liquid through the nozzle. The biggest challenge for this precision is the silicone O-ring at the bottom of the assembly, which prevents the medication in the dosing chamber from running back down the capillary. It requires a standard volume of 7.464 mm3 to minimize evaporation and to remain tight against the high pump pressure. And for this seal, as well as three others in the Respimat, Boehringer Ingelheim microParts turned to Trelleborg.

Trelleborg has invested in cleanroom manufacturing of silicone components and in the production of silicone multi-component products for the pharmaceutical and medical industries

A) Large O-Ring - upper section. B) Smaller O-Ring - lower section

www.trelleborg.com With an ordinary inhaler, much of the medication simply gets swallowed. Not with the Respimat® Soft Mist™ Inhaler, though, thanks to pioneering design

High-purity TPV medical elastomer range extended From ultra-soft to new high-hardness grades, all without need for pre-drying TEKNOR Apex Company has developed two high-hardness grades in its Medalist® MD-200 series of thermoplastic vulcanizate (TPV) elastomers, extending the already broad durometer range of these resilient, high-purity compounds for replacing rubber in medical applications, the company announced today. Previously ranging in Shore A durometer from an ultra-soft 15 to a semi-hard 80,

the Medalist MD-200 Series now includes an 87 Shore A compound, MD-240, and a 43 Shore D grade, MD-245. The 43 Shore D durometer is roughly equivalent to a Shore A hardness of 93. The new compounds can be extruded, injection moulded, and blow moulded. Suggested applications include peristaltic tubes, collection and drainage tubes, stoppers for vials, caps and plugs, seals and gaskets, device handles, ergonomic soft grips, valves, and diaphragms. The rubber-like properties of Medalist MD-240 and MD-245 include low longterm compression set, high fatigue resistance, prolonged ﬂex life, stability at high temperatures, abrasion resistance, and long-term sealability. [A table of properties

62 FEB / MAR 2013

accompanies this news release.] Teknor Apex produces Medalist compounds in dedicated ISO-13485-certiﬁed facilities. All standard grades are FDA, RoHS, Coneg, and REACH compliant, are Drug Master File (DMF) listed with FDA, and are biocompatibility tested in accordance with ISO-10993-5. Teknor Apex has developed extensive data for all grades on chemical resistance and resistance to steam, gamma, and EtO sterilization. Medalist compounds are free of animal-derived materials, phthalates, latex proteins, and bisphenol A. • TEKNOR APEX IS REPRESENTED IN SA BY ADVANCED POLYMERS

medalist@teknorapex.com

www.teknorapex.com

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MATERIALS

VW Golf front end carrier

made only from plastic One of the world’s first front end carriers without metal reinforcement THE FRONT END carrier in the new Golf 7 is completely made from plastic. This makes the part that owes its shape to elaborate calculations and simulations one of the world’s first front end carriers without metal reinforcement. Replacing the previous polypropylene hybrid part with an all-plastic part required use of not only Ultramid® B3WG8, a highly reinforced polyamide during development, but particularly Ultrasim®, the simulation tool from BASF. The sheet steel parts that had been attached previously are now eliminated. This reduces the weight of the front end module significantly compared to that of the predecessor model, saving assembly time and thus costs. Volkswagen produces the part in-house. Intelligent design with Ultrasim In addition to limited space for installation, the requirements to the all-plastic part include a variety of very challenging load cases: among them, static and dynamic hood latch failure, where incorrect opening and closing of the engine’s hood is simulated and tested under the harshest conditions. At the same time, the stiffness

and vibration behaviour of the system comprising front end and radiator was optimized on the basis of CAE analyses and validated in an actual vibration test. Crash sensor: correctly predicted Special attention was devoted to the crash sensors attached to the front end. They ensure deployment of the airbag at the right moment in the event of a headon collision. For this, the plastic part must exhibit a certain dynamic stiffness at a deﬁned location and satisfy the automaker’s crash acceleration requirements. In a real-world test, the vibration response of the part corresponded exactly to what was designed and predicted by Ultrasim: The Ultramid front end carrier transmits the collision signal correctly. Precision with Ultramid plastic and the Ultrasim CAE tool The primary load cases provide the basis for a front end design; from these, an optimized topology can be derived. This topology gives the designer valuable informawww.ultramid.de

www.ultrasim.net

tion regarding the final shape of the part. Thanks to the highly accurate predictions of Ultrasim, only slight modifications were needed in moving from the prototype of the front end carrier to its serial production. This demonstrates the kind of challenging applications that can be addressed by combining a suitable material with the correct prediction and calculation tools. Ultrasim, together with its special failure models, can also be integrated seamlessly into the calculation environment for the automaker’s entire vehicle. This requires, however, that very specific, e.g. crash-relevant material data for the plastic be available which describe exactly the effect of temperature, moisture and rate of load application. A simulation is thus preceded by acquisition of extensive material data from experiments conducted with the aid of complex testing and measuring instruments. The simulation tool is then able to predict failure behaviour, strain rate dependence, and even tension compression asymmetry as a function of fibre orientation. www.basf.co.za

64 FEBRUARY / MARCH 2013

A front end carrier without metal reinforcement has gone into production at Volkswagen as an all-plastic injection moulded part. The part is installed in the new Golf 7 and consists entirely of Ultramid® B3WG8, a polyamide from BASF. Through use of Ultrasim®, the company’s universal simulation tool, it was possible to develop a very sturdy yet lightweight part. This allowed the weight of the entire front end module to be reduced considerably compared to that of the preceding model.

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 tre treat water for safe drinking.

Styrolution streamlines product portfolio

MATERIALS

Changes affect polystyrene, ABS, SAN products and ABS polyamide blends IN A significant move to simplify customers’ buying experience, Styrolution has made a strategic decision to harmonize selected product lines into a unified product portfolio as from 1 January 2013. Since the joint venture between BASF and INEOS in October 2011, Styrolution’s products have been marketed under various inherited brand names. For the last year, these products have been marketed in SA by Plastichem, Styrolution’s South African distributor, and Thread Management Limited, Styrolution’s distributor for sub-Saharan Africa. The changes which came into effect on 1 January will affect Styrolution’s polystyrene, ABS, SAN products and ABS polyamide blends and will make the naming structure more intuitive when selecting the right material to meet a specific need. The product nomenclature, formulations, structures and performance remain unchanged.

Polystyrol® and Empera® brands All standard ABS products will be marketed under the brand name Terluran® All specialty ABS products will be marketed under the brand name Novodur®, replacing the former Terluran and Lustran specialty brands All SAN products, will be marketed under the brand name Luran®, replacing the former Lustran SAN brands The ABS and polyamide-based thermo-

plastic polymer blends, Terblend® N and Triax®, will be consolidated and marketed under the brand name Terblend® N Branding and product grade nomenclature on all remaining speciality copolymers and blends remain unchanged. www.styrolution.com www.plastichem.co.za

Consolidated product portfolio Brand names will change as follows: All polystyrene products are now marketed under the new brand name Styrolution PS, replacing the former

PTFE for extreme conditions Durability and longevity for seals, bearings, washers QUADRANT Engineering Plastic Products (EPP) has delivered a step-change in durability and longevity to seals, bearings and washers used in fluid processing with the launch of advanced Polytetrafluoroethylene (PTFE) Fluorosint® 135. The new material grade’s unique combination of lowest coefficient of friction (COF), lowest coefficient of linear thermal expansion (CLTE) and lowest wear rate outperforms typical filled PTFE compounds to offer machines the best protection against wear and breakdown, even at extreme temperatures and pressures. Fluorosint 135 is engineered for superior performance and value. The new material can be used at temperatures up to 232°C. Tests conducted indicate an advantage in CLTE, COF and deformation under load of over 30 to 50%. These properties provide a major improvement compared to other filled PTFEs on the market, and create significant advantage in enhancing part performance and increasing part life. 66 FEBRUARY / MARCH 2013

The extreme chemical inertness of Fluorosint 135 protects components and reduces the risk of malfunction due to corrosive chemical attacks. This makes it ideal for chemical processing applications, as well as more general ﬂuid processing environments. Fluorosint 135 is designed to improve the performance of compressor piston rings, rider bands, and packing seals, used in pump, valve and compressor

Quadrant Engineering Plastic Products (EPP) delivers a step-change in durability and longevity to seals, bearings and washers used in ﬂuid processing with the launch of advanced Polytetraﬂuoroethylene (PTFE) Fluorosint® 135

wear parts. Available in a wide range of rod, tube, and sheet sizes, the new material is further evidence that Quadrant is at the forefront of plastics’ innovation, engineering, and design. www.quadrantplastics.com

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

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MORE CHOICE FOR:

MATERIALS

Blow moulders with SABIC’s PP Qrystal family New PP grade offers enhanced transparency at lowered processing temperatures TO PROVIDE options for extrusion blow moulding, companies looking for a costeffective, clear and stiff material for their small and medium-sized bottles, SABIC has developed a new, high-clarity Qrystal polypropylene. These random copolymers

SABIC’s PP Qrystal QR681K is typically suitable for packaging household chemicals, as well as typical shampoo and personal care applications; it has a melt ﬂow rate of 2.2 g/10 min, which provides convertors with good parison control, while reducing machine torque and melt pressure

were designed with notable flow behaviour, providing processors with the flexibility to potentially produce parts faster and with lower energy consumption. SABIC® PP Qrystal QR681K has a melt flow index rate (MFR) of 2.2 g/10 min, which provides converters with good parison control, while reducing machine torque and melt pressure. These features, coupled with optimized die swell, give them the chance to further optimize the wall thickness of their bottles, and possibly attain important weight savings. The material also has good impact strength – as well as the chemical resistance typical of polypropylene, making it typically suitable for packaging household chemicals, as well as typical shampoo and personal care applications. The new material is intended for containers up to 5 litres in volume.Although principally targeted at extrusion blow moulding (EBM), tests by SABIC on injection blow moulding (IBM) equipment have also yielded promising results. “The combination of the enhanced transparency at lowered processing temperatures and its weight saving potential can be utilized by processors to save

energy and/or reduce cycle times without any negative effect on product quality,” says Marnik Vaes, technical marketing engineer for PP at SABIC. “This can be a sustainable solution to decrease the moulded article carbon footprint and its unit cost structure.” SABIC’s customers now have an even broader package of PP random copolymers to choose from that provide possible solutions for a wide range of applications and processing techniques, providing a combination of good transparency with potential lower conversion costs. The PP Qrystal range now comprises ﬁve grades, with MFRs ranging from 2 to 80 g/10 min. All SABIC PP Qrystal grades offer converters a good balance of impact strength and stiffness and enable them to produce parts with no loss of transparency or aesthetics. They meet the precise demands of customers in markets such as injection moulded housewares, ofﬁce and home storage, lids and cap & closures, as well as blow moulded products. The levels of transparency and gloss make the resulting products highly competitive on the shelf. www.sabic.com

From design to reality WHEN Fonckel B.V., a start-up company based in the Netherlands, needed expert assistance to turn the stunning design of its Fonckel One lamp – an interactive light emitting diode (LED) luminaire – into a commercial product, SABIC’s Innovative Plastics business was there to deliver its worldclass customer support. With its robust portfolio of advanced thermoplastics for lighting applications, its Colour Innovation Centre offering more than 18,000 colour and diffusion effect options, and its application development expertise, SABIC assisted Fonckel with tapping the proven performance and versatility of LEXAN™ FXD polycarbonate (PC) resin for use on the lamp’s diffuser cover. On display here at the Strategies in Light Show at SABIC’s booth, this unique luminaire, the name which means ‘sparkle’ in Dutch, demonstrates SABIC’s ability to precisely meet the specialized needs of its customers by helping them translate their design vision into the right material application. www.sabic-ip.com

New generation tribological compounds LEHMANN & Voss & Co. have developed a new generation of tribologically optimized materials under the name of Luvocom® XSL. The first material in this new product family is Luvocom® 80-8656/XSL, based on POM. Its exceptional tribological properties can also be seen in a comparison with modifications using traditional additives such as PTFE and silicone oil. The lubricant in Luvocom 80-8656/XSL functions during the entire operating life of the component. No additional greasing is necessary. Processing takes place on conventional injection moulding machines. Due to the low friction coefficient in many cases it is possible to manage without a draft angle. Luvocom 80-8656/XSL is not reinforced which means that snap connections and undercuts are possible. Modifications adapted to the requirements are possible with reinforcing materials such as glass fibre, carbon fibre, aramid fibre and other additives. www.lehvoss.com 68 FEBRUARY / MARCH 2013

www.luvocom.de

Holes for protection BARELY two years after its introduction, the high-temperature resistant engineering plastic Ultramid® Endure from BASF has found its ﬁrst production application: The company, Montaplast, Germany, a global supplier to the automotive industry, is using the polyamide specialty Ultramid Endure D3G7 for a heat shield in the charge-air manifold used on the 4 cylinder diesel-powered automobile engine from Daimler. In the air intake region of the chargeair manifold, which features integral exhaust gas recirculation, fresh air and hot exhaust gases are brought together. This is where high mixing temperatures and strong turbulence are encountered. Until now, an aluminium shield provided protection for the wall and a built-in sensor. Now, a heat-resistant plastic insert fulﬁls this function. The special heat aging resistance of Ultramid Endure comes into play here: The material easily withstands a continuous service temperature of 220°C and peak temperatures of 240°C. Stabilization technology that creates a protective surface layer on the plastic is responsible for the high heat resistance of this polyamide specialty.

the Ultramid Endure heat shield to produce a speciﬁc turbulence in the charge air. Moreover, the weight of the plastic part is only half of the previously used aluminium part. The engine compartment is becoming increasingly compact and thus hotter. At the same time, the vehicle should become lighter by substituting plastic for metal. Because of their high system costs, however, high-performance plastics are ruled out. The new polyamide Ultramid Endure combines its exceptionally high heat

aging resistance with the good processibility of PA66 – the characteristic that is the determining factor when it comes to system costs. The material is thus an ideal alternative for applications all around the charge-air system in modern turbocharged engines. Thanks to the design freedom that the injection moulded plastic provides, the automotive supplier can address the individual requirements of a vehicle manufacturer speciﬁcally. www.ultramid-endure.basf.com

The new heat shield in the air intake of the 4-cylinder diesel-powered automobile engine from Daimler is now being produced by Montaplast from an engineering plastic: the ﬁrst production part manufactured from the new exceptionally heat-resistant polyamide Ultramid® Endure from BASF

Perforation for favourable ﬂow Two additional properties of the plastic distinguish the new heat shield from its metal predecessor: First, the plastic functions as a thermal insulator. Additionally, it was possible to incorporate openings in

PHOTO: BASF

MATERIALS

First production application for the new heat-resistant BASF polyamide Ultramid Endure

Plant-based plastic range wins eco-design award THE ROQUETTE Group, a global player in the processing of plant-based raw materials, was distinguished with an Eco-Design award for its GAÏALENE® plant-based plastic range at the Annual Sustainable Development and Enterprise Days (JADDE) held in Lille, France in October. Alongside Roquette, the company Elise, which specializes in paper recycling, was also acknowledged with an Eco-Design award for their office basket designed by Philippe Starck and manufactured from GAÏALENE® plant-based plastics. The new office receptacle, ELISEbySTARCK®, is stylish and refined with soft, tactile qualities, available in several colours and is offered to all of Elises’s customers to help collect waste paper and other recyclable materials such as batteries. www.gaialene.com

www.elise.com.fr

70 FEBRUARY / MARCH 2013

www.roquette.com

The new ofﬁce receptacle, ELISEbySTARCK®, is stylish and reﬁned with soft, tactile qualities and is available in several colours

COMPOSITES

Space age manufacturing Industrialising carbon nanotechnology, making it available to everyone FUTURISTIC carbon materials incorporatBeyond limits ing advanced nanotechnology are currently Future Carbon has pushed the boundaries being evaluated by a number of South of carbon nanotechnology by harnessing Africa’s top manufacturers ranging from airthe findings of Germany’s top academcraft and shipping to geysers and electronics and inventing industrialised uses and ics industry leaders. products for them. According to company Cutting edge nanotechnology can be inCEO Tomas Meinen, who recently visited corporated into everyday products and has South Africa to introduce the product range, the ability to give materials super-properties new uses are being found for the material far beyond the normal range. It incorporates every day. Already the automotive industry the use of tiny particle based materials has begun widely using nanotechnology for that effectively increases surface area at a uses as diverse as impregnating leather for molecular level to lend certain enhanced heated seats, as well as spray-on technolcharacteristics to a material. ogy for heated panels and additives for For years academics batteries to give them around the world have super-long life. Nano-materials are known of its attributes Nano-materials are alalready being widely such as super heat or ready being widely used used (or tested) by electrical current conduc(or tested) by manufacturtivity, shielding, strucers overseas in hundreds manufacturers overseas tural strength, elasticity, of other applications. in hundreds of other chemical resistance and a Properties of low-voltage applications. myriad of other attributes. conductive heat coatings, But German technology EMC coatings and mefirm, Future Carbon, has become the first chanically reinforced resins are being used advanced technology company to find ways for industrial application. Interesting uses of of industrialising the technology and making the technology include low-voltage conducit available to the general public. tive heating coatings (Carbo e-Therm) for Future Carbon CEO, Tomas Meinen

industrial food processing equipment to coat drums and other surfaces such as vessels, conches, and pipeline systems for large-scale food preparation. EMC coatings (CarboShield) provide electromagnetic shielding (protection against electromagnetic radiation), inter alia, for the aerospace or automotive industry to protect satellites and aircraft electronics from electromagnetic interference or onboard electronic systems of vehicles. High performance low-voltage heating coatings (Carbo e-Therm) are used to temper satellites, for aircraft cabin or instrumentation heating and de-icing. Mechanically reinforced resin systems (CarboForce) are employed in the aerospace, automotive or construction industry to dramatically improve structural strength (improved mechanical characteristics) of materials to allow engineers to push the boundaries of modern-day design and construction.

Basic principle of a continuously running automatic production system for high quality composite parts 72 FEBRUARY / MARCH 2013

Better way During the high-proﬁle introduction of the materials to South Africa, Jo Jacinto of Advanced Materials Technology (AMT), the local representative for Future Carbon in

Spray on application of low voltage heating material

South Africa, showcased yet another of the technology’s abilities to heat-cure carbon fibre and resins in heated moulds. Making use of Pretoria-based aerospace technology leader Aerosud’s technical facilities, a low-voltage heating coating with high power density was applied to moulds to allow quick and even curing of carbon fibre and resin materials. “In the past heat-cured materials needed to be cured in kilns or ovens and depending on the size were often prohibitively expensive. The introduction of spray-on heat coatings however, dramatically improves the way moulds are made and gives mould-makers the ability to produce heated moulds in any shape or size, coat it and evenly heat it to as much as 500°C,” said Jo. He added that the thin surface layer heats instantaneous when a current is applied and provides uniform distribution of heat to all areas. Future Carbon mesh materials and impregnants can also be used for silicon or other moulds allowing faster and potentially stronger carbon fibres to be produced. During the demonstration AMT and Aerosud technical staff showed how easy the technology is to apply by quickly producing the country’s first nano-heated mould that will be used to manufacture props to fit the popular Samba aircraft. In most instances nano-materials are added at a ratio of below 1% and so do not change the base composition of the material. “Manufacturers can enhance the properties of their products or invent new ones through the application of the world’s most advanced nano-additives, coatings or adhesives available from AMT,” Jo said.

Even distribution of heat is evident on the infrared camera

Some advantages of Direct Mould Heating (DMH) / In-Mould Heating (IMH) Active temperature control: stable process conditions independent from changing ambient temperatures Always controllable infusion process thanks to stable or adjustable mould temperature Always stable process parameters: excellent reproducibility and quality control Continuous production possible (no batch processing) by integration of the entire thermal regime into each mould No autoclave necessary

www.amtcomposites.co.za

High energy-saving potential

FEBRUARY / MARCH 2013 73

The integrated control panel (ICP) forms the centrepiece of the dashboard. The plastic switches are pre-treated with Openair atmospheric plasma before painting to ensure a ﬂawless ﬁnish and an adhesion that will last for years

Good as new for years Micro ﬁne cleaning & activation of plastic surfaces in one operation BY INÈS A. MELAMIES, BAD HONNEF, GERMANY

A flawless paint finish and long-time stable adhesion cannot be achieved without micro fine cleaning and activation of plastics, like PC, which are resistant to adhesive bonding. Since the solvent-based primers often used to increase adhesion are harmful to the environment and costly to dispose BMW, for example, requires the paint of, it is clear that in an age of greater used for rotary switches to be sufficiently environmental awareness, car manufacwear-resistant to withstand being turned turers must seek alternative solutions; through 360° no less than 60 000 times the trend is shifting towards water-soluble before the paint shows any signs of dampaints and environmentally friendly preage. Standard pushbutton switches, such treatments. as CD or climate controls, must be able to Some years ago when Daimler asked withstand at least 100 000 touches. This its supplier TRW Automotive Electroncorresponds to an assumed load over a ics & Components GmbH in Radolfzell, 17 year period – regarded by BMW as the south Germany, total life cycle of the Openair atmospheric to provide a vehicle. Other prefurther cleaning mium brands have plasma technology is stage – in addisimilar specificaa process that allows micro fine tion to the ioniser tions, which means cleaning and activation of already used to the supplier must non-polar plastic surfaces in remove dust from offer the same high a single operation components – and standard of quality was also planning to all his customers. to switch to water-based coatings, the Keeping these painted plastic interior supplier was faced with a problem; the components looking as good as new for power wash process requested by the car years is a challenge which German manumanufacturer proved to be unworkable facturer meets head on by pre-treating right from the test phase. millions of switches and controls with Kerstin Tietz, senior engineer in atmospheric pressure plasma. the Industrial Engineering, Painting & Laseretching division at TRW Radolfzell, No easy matter recalls: “Our tests showed that power Pre-treatment of the material surface is washing simply blasted away our tiny the starting point for meeting the rigorous components, only a few centimetres in diquality requirements of the paint process.

Automotive manufacturers place stringent demands on the quality of the ﬁnish of all their vehicle components, not least the interior dashboard, arguably the most ‘handled’ part of any car.

74 FEBRUARY / MARCH 2013

ameter, or blew them onto one another so that they got scratched. On top of that, the water got trapped in the jig moulds. We drilled holes in the jigs and even modified the containers, but it was no use”. A CO2 treatment which was considered as a possible alternative proved equally disappointing: Again the components were blasted out of their moulds. This method was not just intolerably loud, but also expensive, as extra space had to be created outside to accommodate the tanks. Although there was no question that both methods offered good cleaning power and would have been appropriate for heavier components, what they lacked was activation capacity. This meant that an additional system would have been needed to provide the activation required for water-based coatings. TRW initially thought that fluorine technology would provide the answer, but preliminary trials proved otherwise: After treatment, some of the PC components were iridescent blue and some transparent. Furthermore, they had to be sent to an external service provider for the pre-treatment and this dependence was too great a risk for the manufacturer, who works in series production. And besides, the process was not environmentally friendly. TRW conducted further research and discovered a process that not only enabled micro fine cleaning and activation of the non-polar plastic surfaces in a single operation, but did so without causing any of the problems referred to above, or

TECHNICAL even creating new ones: Openair atmospheric plasma technology.

AP plasma in the paint process Today TRW manufactures sensors, keyless entry systems and switches and switch mechanisms for systems inside the vehicle designed to enhance control and comfort for car manufacturers such as Daimler and Ford.

Fig.1 – The Openair plasma system (3rd unit from the front) takes up only one metre of a painting line with an overall length of 25m

From injection moulding and painting to laser cutting and electronics manufacturing, most of the components are produced, assembled and tested in-house. The ﬁrst system supplied on loan by Plasmatreat to perform the test runs was quick to gain admirers. “It was easy to operate, clearly laid out, quiet, safe and didn’t take up much space,” says Kerstin Tietz. After the test phase a production plant equipped with two plasma jets was initially used. But as volumes increased, a larger painting line was required and paint line manufacturer Venjakob Maschinenbau GmbH & Co. KG was commissioned to integrate a plasma system connected in series immediately upstream of the paint station right from the outset. In spring 2011 the new 25m long painting line – in which the plasma system takes up only a metre – was up and running. Six patented type RD1004 rotary plasma nozzles have since been working in-line around the clock (Fig. 2).

Each week they clean and activate around 180 000 visible parts made from PC or (PC+ABS) blend prior to painting (Fig.3), ranging from simple 2-D components to complex 3-D geometries such as steering wheel covers. Each individual switch component is visually inspected before a laser applies the ﬁnal markings (Fig. 4). The TRW factory incorporates all the little switches and buttons into around two million complete ICPs (Integrated Control Panels) per year (Fig 5). Summary A high degree of process reliability takes precedence at TRW and this is achieved through the computer-controlled and screen-monitored plasma system. It enables the factory on the shores of Lake Constance to manufacture several million buttons and switches annually. “Using the Openair technology was the right decision for our company. The system gives me peace of mind”, is how Kerstin Tietz summed it up, before adding:

Fig.2. – Six rotary plasma jets work in-line around the clock. Each week they clean and activate 180,000 visible parts made from PC and (PC+ABS) blend in a single step

PHOTOS: PLASMATREAT

Cleaning and activation in a single step The plasma jet technology developed by the German Plasmatreat GmbH almost 20 years ago is now used throughout the world in a wide range of industries. The environmentally friendly in-line process works under normal ambient air conditions, thereby dispensing with the need for a vacuum chamber. The system performs three operations in a single process lasting only a matter of seconds: It simultaneously brings about the micro fine cleaning, electrostatic discharging and strong activation of the plastic surface. Activating a material surface increases its surface energy (dyne). This is ultimately the most important measure for determining the probable adhesion of a paint or coating. Plastics generally have a low surface energy between < 28-40 dyne. But experience shows that only surface energies above 38-42 dyne offer the right conditions for adhesion. Reliable paint adhesion is conditional on the surface energy of the solid material being higher than the surface tension of the liquid paint. Whilst immediately after injection moulding the surface energy of PC components at TRW was only 32-34mJ/m², it increased to values of 5658 dyne, and in some cases even in excess of 72mJ/m² following plasma treatment. Peter Langhof, market and project manager at Plasmatreat, explains: “The dual effect of micro fine cleaning and simultaneous strong activation far outweighs the effectiveness of conventional systems. This produces a homogeneous paint finish and long-time stable adhesion of the coating even under the most challenging load conditions” (Fig.1). The rise in temperature of the plastic surface during plasma treatment is typically less than 30°C.

PHOTOS: PLASMATREAT

TECHNICAL

Fig.3. – The dual effect of the atmospheric plasma treatment far outweighs the effectiveness of conventional systems

“For us the pre-treatment has proved proﬁtable, simple and effective. It has enabled us to meet our customers’ stringent requirements.” Throughput has tripled since the company started using the new painting line with integrated plasma system and stopped using primers. Furthermore, not only has a complete run incorporating six operations been dropped, it

Fig.4. – Is the paint ﬁnish ﬂawless? Each individual switch component is visually inspected before a laser applies the markings

has also been possible to save a great deal of time and 90% of the energy costs compared with using other cleaning systems and primer activation. Fig.5. – At TRW Radolfzell around two million complete ICPs (Integrated Control Panels) are manufactured per year

• PLASMATREAT GMBH IS REPRESENTED IN SA BY RESIN PROCESSING SOLUTIONS www.plasmatreat.com

76 FEBRUARY / MARCH 2013

R.P.S. cc Resin Processing Solutions

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

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TRAINING

Students point the way to

GREAT industrial design Design is a key strategic business tool IF South African companies involved in product manufacture wish to compete successfully, they need to invest in design and accept that the design factor is internationally recognised as a key strategic business tool, says Mike Wythe, industrial designer and lecturer for the Industrial Design Programme at the Tshwane University of Technology (TUT).

BEST L L V O ERANT E STUD D AWAR

Best overall student award 2012 “Taking design to the next level” is the working ethos of young designer Martin Venter. Moving away from conventional styling, he introduced a level of fun into the arduous task of cutting and trimming the lawn. Taking note of the idea that the basic mechanical product need not be boring, this design explores the wide limits of the injection moulding process and achieves a unique balance between form and function. 78 FEBRUARY / MARCH 2013

Students in the Industrial Design programme at TUT are pointing the way. Meeting the challenges of the final project to design a dual function mower/trimmer, the third-year students not only gave consideration to the important aspects of function, aesthetics, end-user requirements and market acceptance, but also to optimum production methods. For the project, the students produced support documentation as evidence of their understanding of manufacturing processes. A detailed CAD package of productionready drawings backed up their design endeavours. The final specification package prepared by each student defined the precise structural geometry and material specification for each of the plastic components making up the final assembly. “Injection moulding is the preferred manufacturing process; any one of the concepts presented by the students at their end-ofyear exhibition would require a number of moulds to be made if ever the product was to be taken to market. Proving somewhat

simplistically that before you can develop a tool making industry you must first design the products!” adds Mike. “By establishing pro-active initiatives we can make design work for our economy and start manufacturing products that will not only meet the needs of both domestic and sub-Saharan markets, but also siphon off some of the lucrative rewards that can come from exporting well designed value added products,” he says. Project scenario Students were told that the marketing department of a garden equipment manufacturer had recognised a potential sales opportunity in both domestic and export markets for a single dual function machine that can deliver two specific but independent functions - either as a lawn mower or be re-configured to operate as a versatile handheld weed eater/trimmer. This year’s TUT industrial design students all demonstrated high levels of creativity and innovative thinking in what they came up with …

Yachel Croft adopted a technical approach to solve the dual function problem. Mounting two motors that can be activated separately by switches in the handle, the end-user can select the speciﬁc operating mode required. The small motor when activated automatically rotates a section of the lower chassis through 180 degrees. This action exposes the trimmer function; by activating the small motor again the process is reversed changing the machine back to the mower conﬁguration. The large motor is there to power both trimmer and mower cutting functions, the housing for both motors and the main chassis components are manufactured from ABS/PC blend.

WELL TO DONE E S E TH NTS! STUDE

HIGHLY COMMENDED

Highly commended

Jonathan Green’s ﬁnal product was inspired by the STIHL brand’s clean aesthetic geometry. The dual function feature is achieved by simply releasing the motor and trimmer assembly from the mower chassis. The ﬁnal product is manufactured from ABS and a copolymer PP.

Olona-ncedo Magokolo chose to take an advanced look at the overall aesthetics and style of the product. Looking carefully at the RYOBI brand, this concept delivers very well against the specifics of the design brief. In taking this route the concept would not only fit well into the RYOBI stable, but also deliver against specifics of a dual function machine.

In this scenario, Erika van Heerden has taken on the role of consultant to a company, which often requires the use where possible of existing tooling or stock items. The challenge here was to give the new dual function product a FLYMO brand identity. Following the company directive, Erika has successfully achieved the objective; remaining consistent to the FLYMO style, using stock items where possible, and using existing tooling and applied proven material speciﬁcation in this case ABS.

Ricardo Brunido adopted a slightly less conventional way of achieving the design brief. By keeping to the fixed unit concept, he developed a simple system of re-aligning the handle with the main base chassis; by activating a foot pedal the operator can easily turn the mower into a trimmer configuration without the need to detach one from the other. Strength, durability and quality of finish were taken into consideration when selecting an ABS/PC blend as the production material for this concept product.

Highly commended

Wessel Wessels addressed the speciﬁc needs of the small townhouse garden owner. This design delivers a compact, versatile, functional solution. There is no need to separate any part of the product one from the other to turn the mower into a trimmer. This is achieved by simply sliding part of the base chassis to one side exposing the Polypropylene trimmer ﬁlament. If the operator needs to access tight areas when in trimmer mode he/ she can move the handle through 90 degrees and lock it into position. A simple operation that changes the cutting angle of the trimmer, reversing these operations will quickly changes the trimmer back to mower mode.

Lesley Motsuenyane took the direct approach. The three-wheel conﬁguration allows for easy mobility when set up as a mower and by simply removing the front section of the mower chassis, the trimmer is exposed. The pair of offset rear wheels also facilitate the easy control of the machine when in trimmer mode. ABS and PP were selected as the optimum materials for this product.

FEBRUARY / MARCH 2013 79

Students point the way to

GREAT industrial design

Thato Pitse took a very analytical approach to solving the dual function problem. The concept design presented by this student is the result of extensive ergonomic research and the application of the fundamental factors of design; use, manufacture, business, environment.

Henk Swanepoel pursued the simple premise that the garden in an organic environment. While retaining the WOLF brand image, this design has captured the fundamentals of easily moulded components; large soft radii, no sharp corners, well deﬁned geometry. The materials selected for this product are PP and ABS.

Mike Wythe, industrial designer and lecturer at the Tshwane University of Technology with a group of 2012 ﬁnal year Industrial Design students

80 FEBRUARY / MARCH 2013

TRAINING

N IS DESIG Y E K A EGIC STRAT ESS IN BUS L TOO

Ntwanano Mamitwa’s design delivers against the brief very well; the streamlined aesthetics ﬁts neatly within the RYOBI brand image. Dual function capability is achieved by separating the motor housing from mower housing. Following extensive ergonomic trials the user-friendly issues of product balance and operation in either mower or trimmer mode have been resolved. The majority of the components making up the ﬁnished assembly are injection moulded; a number of tools will be needed if this product was to go into production.

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AWARDS

Automotive innovation nd

FOR the 42 year in a row, members of the SPE Automotive Division’s board of directors and their guests met in Michigan, USA, in November to honour the year’s most innovative use of plastics in ground transportation at the SPE Automotive Innovation Awards Gala. Winners survived a prequaliﬁcation round as well as presentations before a panel of industry of experts during September and ﬁnalists from that round presented before a Blue Ribbon panel of judges in October where category and Grand Award winners were selected. This year’s Body Interior category winner was also voted the Grand Award winner. Other winners were as follows.

GRAND AWARD & CATEGORY: BODY INTERIOR ALL-OLEFIN, SOFT SKIN, STITCHED FULL IP SYSTEM OEM make & model: General Motors Co. 2013 MY Buick® Enclave®, Chevrolet® Traverse®, GMC® Acadia® SUVs Tier supplier/processor: Inteva Products, LLC Material supplier/toolmaker: Adell Plastics, Stahl, Ticona Engineering Polymers / KTX

GRAND D AWAR R WINNE

Material/process: TPO-631 SSXT Soft TPO, Celstran® LFT-PP / multiple processes

These midsize crossover vehicles demonstrate the use of contour stitching on an all-oleﬁn, multi-grained full instrument panel (IP) surface with complex geometry. Advanced robotic sewing technology provides an ‘up-level’ appearance while saving 15-25% costs vs. non-cut/sew applications and up to 50% vs. cut/sew leather plus 15% weight.

CATEGORY: CHASSIS/HARDWARE

CATEGORY: BODY EXTERIOR

DUAL-RATE AIR EXTRACTOR

CARBON COMPOSITE HOOD ASSEMBLY

OEM Make & model: Ford Motor Co. 2012MY Ford® Escape® & Edge® CUVs

OEM Make & Model: Chrysler Group LLC 2013 model year (MY) SRT Viper® supercar

Tier supplier/processor: Wegu Manufacturing Inc.

Tier Supplier/Processor: Plasan Carbon Composites

Material supplier/toolmaker: Rhetech / Anfe-Moulds Inc.

Material Supplier / Toolmaker: Umeco plc/Cytec Industries (carbon ﬁbre weave prepreg); Toray Carbon Fibres Americas, Inc. (unidirectional carbon ﬁbre prepreg); Ashland, Inc. (structural polyurethane adhesive) / Weber Manufacturing Technologies Inc.

Material/process: 40% talc-ﬁlled PP / Injection moulding

Two-shot moulding is used to produce this 1-piece air extractor formed of rigid polypropylene and overmoulded with TPE. The unit features plastic living hinges and plastic torsional springs that function as a 1-way pneumatic valve, allowing air to exit through ﬂaps but reducing the amount of outside noise that can enter the passenger compartment through the extractor.

Material / Process: G83C T700S-24K carbon composite / Vacuum bag, autoclave cure

This hood assembly is a Class A CFRP part with a very large complex clamshell geometry. The painted Class A outer panel is complemented by an exposed weave inner panel. The part represents the largest Class A carbon ﬁbre composite part provided to a mainstream OEM at volumes up to 3,000 vehicle sets/year. Design, tooling, and fabrication technologies from both

82 FEBRUARY / MARCH 2013

marine and aerospace were employed for the ﬁrst time in automotive to facilitate layup of the complex geometry with severe undercuts. Integrated mounting points using riv-nuts and studs are moulded into the inner hood panel. Local section thickness was varied to meet structural requirements. The ﬁnal part, incorporating fenders as well as hood is 44% lighter than the previous hoodonly assembly in SMC, helping improve weight distribution and lower the vehicle’s centre of gravity, for better vehicle dynamics and power-to-weight ratio.

at its ﬁnest!

URING HONO BEST THE HE OF T ! BEST

DESIGN

CATEGORY: SAFETY INTEGRATED HEADLAMP/ HOOD BUMP-STOP BRACKET OEM make & model: Ford Motor Co. 2013MY Ford Fusion sedan Tier supplier/processor: Magna Exterior & Interior Material supplier/toolmaker: Styron LLC/ Advantage Mold, Inc. Material/process: PP / injection moulding

Hood bump stops, together with headlamps, provide stiff resistance to the hood structure when impacted, leading to high HIC values during pedestrian-protection testing. Hood material, shape, and packaging space can also affect HIC performance. Traditionally, the hood bump stop and headlamp attachment bracket are designed as separate components. However, a new integrated 1-piece plastic bracket combines the function of the hood bump stop and headlamp attachment and offers a more efﬁcient way to meet new pending ped-pro requirements. The injection-moulded 30% GR-PP patented part is tunable for a wide range of breakaway load levels, can be used on other vehicles, reduces assembly complexity, and lowered HIC values by ~30%.

CATEGORY: PERFORMANCE & CUSTOMISATION

CATEGORY: MATERIALS

CARBON COMPOSITE AIR EXTRACTOR

CONTROLLED CRYSTALLIZATION RATE TO ELIMINATE PAINT

OEM make & model: General Motors Co. 2012MY Chevrolet Camaro® ZL1 sportscar Tier supplier/processor: TransGlobal LLC / deBotech, Inc. Material supplier/toolmaker: Umeco plc/Cytec Industries, BASF Corp., SABIC / deBotech, Inc. Material/process: MTM Prepreg 57 Series epoxy/carbon ﬁbre prepreg / Vacuum-bag/autoclave cure

This single-piece CFRP composite construction with exposed fabric weave provides a lightweight, functional component that increases downforce at high speeds while providing an aesthetically pleasing appearance. The air extractor makes extensive use of adhesive bonding to join additional components in alternative materials (a polyamide vent screen and a thermoplastic polyester deﬂector). Adhesive bonding also isolates the carbon composite panel from the rest of the aluminium hood, preventing galvanic corrosion.

OEM make & model: Ford Motor Co. 2013MY Ford Escape CUV & Fusion® sedan, & Lincoln® MKZ® luxury sedan Tier supplier/processor: TRW Automotive, Key Plastics LLC Material supplier/toolmaker: Asahi Kasei Plastics North America / Liberty Molds, Inc., J&J Tool & Mold Ltd. Material/process: Leona® 90G60 B3374 PA 6/6 / 6I / injection moulding

To support greater design freedom for any shape and length register vanes while meeting stiffness, durability, and perceived quality requirements, a partially aromatic injection-moulded PA 6/6 / 6I resin was used to boost modulus without increasing wall thickness or adding glass reinforcement to achieve a high-quality, MIC Class A surface without paint. Owing to the ‘kinked’ crystalline structure of the semi-aromatic PA resin, crystallization rate can be better controlled, so parts fully pack out before skins freeze off, leading to a resin-rich surface with a smoother surface and better appearance, eliminating the need to paint.

FEBRUARY / MARCH 2013

DESIGN

CATEGORY: POWERTRAIN WATER OUTLET ASSEMBLY OEM make & model: Nissan Motor Co. Ltd. 2012MY Nissan® Altima® sedan Tier supplier/processor: MPC, Inc. Material supplier/ toolmaker: Solvay Specialty Polymers / Industrial Molds Group Material/process: AMODEL® AS-1933HS PPA-GF33 / Injection moulding

The combination of sequencing, precision timing, multi-slide actions, scientiﬁc moulding, and robotics resulted in a world-class wateroutlet assembly injection moulded in glass-reinforced PPA. This metal-to-plastic conversion, whose main function is to act as a manifold for the cooling system, integrated 2 components into 1 assembly, which features 10 seamless barb ports that feed coolant to and from the transmission cooler, throttle cooler,

heater core, oil cooler, and provides coolant to the radiator. The outlet also includes a press-in-place seal, sealed threaded insert, a wire harness bracket, an oil drip rail, plus it houses the thermostat. The 10 male ports are created without a parting line, which is usually required with conventional injection moulding, and are made possible through precision timing of multiple valve gates and multiple slide actions to properly form this complex product.

CATEGORY: PROCESS / ASSEMBLY / ENABLING TECHNOLOGIES DIRECT EXTRUSION OF BULB SEAL ON COWLS OEM make & model: Ford Motor Co. 2013MY Ford C-MAX® HEV Tier supplier/ processor: Windsor Mould Group Material supplier/ toolmaker: ExxonMobil Chemical / Reis Extrusion GmbH Material/process: Santoprene® 121 50E500 TPV

By directly extruding a bulb seal onto an air-inlet panel (cowl), the application’s functional requirements are met and time-consuming manual installation of the seal is eliminated as a secondary operation. An extrusion die, mounted to a flexible, heated hose and guided by a robot, quickly and efficiently lays down a TPV profile along the edge of the injection-moulded substrate. The fully automated process creates an easily tunable and functional seal that can be handled immediately after extrusion without need for post cure (as with thermoset rubber). The operation is cost-effective, eliminates a secondary operation, maximises sealing to the hood interface with excellent dimensional stability, reduces scrap, and provides high design freedom and process flexibility.

Chrysler Group’s SRT Viper supercar wins VETA FOR the second year in a row, a vehicle from Chrysler Group LLC has been named the Vehicle Engineering Team Award (VETA) winner by the Automotive Division of the Society of Plastics Engineers (SPE®) as part of the group’s 42nd-annual Automotive Innovation Awards Competition. The 2012 VETA winner is the 2013 model year (MY) SRT Viper® supercar from Chrysler Group LLC’s Street and Racing Technology (SRT) brand. VETA recognizes the technical achievements of entire teams comprised of automotive designers and engineers, tier integrators, materials suppliers, toolmakers, and others whose work—in research, design, engineering, and/or manufacturing—has led to significant integration of polymeric materials on a notable vehicle. According to Mike Shinedling, Viper engineering launch manager, SRT Engineering, at Chrysler Group: “The Viper has a long tradition of raising the bar on plastics and composites innovation. Historically, Vipers have been ‘bare-bones/no-frills’ sports cars ‒ something that was acceptable to our most ardent, hard-core customers, but not all potential buyers appreciated. In fact, many loyal Viper customers had been requesting more amenities and features on our next vehicle and our team rose to the challenge. The new 2013 SRT Viper is a performance machine that takes a quantum leap forward by offering world-class levels of feature content, interior trim, and exterior finish, and it does so at a significant weight savings. Plastics and composites were key enablers in creating our most outstanding vehicle to date while directly lowering vehicle mass approximately 45kg.”

FEBRUARY / MARCH 2013

THE DESIGN FACTOR…

BY MIKE WYTHE, M DES RCA (ID ENG), INDUSTRIAL DESIGNER & LECTURER

Proﬁt by Design EXPORTING products with little or no value added while continuing to import goods with substantial added value will not improve the balance of payments status of a country. Well-worn rhetoric – yes! If, however, one takes note of the economic growth achieved by countries like South Korea, Taiwan, China and India then one must accept that they are doing something right. Design, more speciﬁcally the all-encompassing disciplines of industrial, graphic and engineering design, that successfully take a product from concept through to market, are not only the ‘feed stock’ for product manufacture, toolmaking and the sustained growth of the plastic converting industry, but also the professional disciplines that can form the springboard for sustainable economic growth, small industry development and job creation. If companies involved in product manufacture wish to compete successfully they

must invest in design. If a country like ours has an urgent need to develop its manufacturing base, stimulate growth in the small to medium sized business sector and ultimately create employment it has to accept the design factor as a key strategic business tool. If we are to stimulate and develop the sustained growth of our toolmaking and plastic related industries and by default start manufacturing more products, we must accept product innovation, product development and design as essential pre-requisites to this endeavour. Ingredients for success Start from within: Design must grow from inside. If applied only to the outside, the ﬁrst brush with competition easily rubs it off. Design must be an attitude of mind, a ﬁrm belief and a passion. Design in the boardroom: For design

to ﬂourish in a business, one of the board members must take responsibility for it. He or she can then drive the design message and commitment downwards to all corners of the company. Include all the company’s products: Many companies regard design as a technique to ‘tart up’ a product range. Devoid of design, heart and soul, these companies are doomed to competitive failure. A regime of design quality should be established in all your products and services – no item is too trivial. Co-ordination is vital. Involve all the company’s staff: Any designers, who regard design as uniquely their own responsibility, jealously guarding their design empire from sales, production, marketing, or others, are their employers’ worst enemies. Design should be understood and fostered in all departments.

Another Dyson industrial design bound for thousands of homes around the work – the supercool Space Heater

Dyson continues to innovate by introducing his latest product, the ‘Bladeless Fan’

British industrial designer, Sir James Dyson, is best known as the inventor of the Dual Cyclone bagless vacuum cleaner. Dyson developed over 5 000 prototype designs between 1979 and 1984 before he successfully launched his cyclone vacuum cleaner. His net worth in 2011 was said to be £1.45 billion. 86 FEBRUARY / MARCH 2013

FEATURE Good internal communication: If design policy and philosophy is fully disseminated throughout the company, differing interest can produce constructive dialogue, rather than conďŹ&#x201A;ict. Get help: Donâ&#x20AC;&#x2122;t be insular about design. Be prepared to seek expert help. Many consultants have an excellent record of hard-nosed commercial success in corporate and product design. Use them, learn from them, and then let your staff be your design dynamic. Know what your customers want: Directors in many industries put the blame on designers for products, which are inappropriate for their markets, when these are precisely what the board originally speciďŹ ed. Hire professionals: Although design must be company-wide and company-deep, an experienced design manager must be appointed and given the authority and investment to carry design through all its stages. Train everyone: Successful public and private enterprises with high design proďŹ les appear as efďŹ cient, slick operations. Do not be fooled by the image â&#x20AC;&#x201C; their positions are hard won. All these organisations have a full and continuing training programme to drive home how design affects every aspect of their business. Never be satisďŹ ed: The most effective design strategies are relentless. Markets and competitors change with the speed of light. Only by constant re-analysis, re-training and re-direction can a company stay ahead. Design as investment: Design costs money and good design can be expensive in the short term. But it is one of the best investments your company will make for future business. Find out what percentage of your budget is spent on design â&#x20AC;&#x201C; is it enough? Are there items in the companyâ&#x20AC;&#x2122;s range ripe for improvement by design? Might design input lead to product developments? Design investment can strengthen a companyâ&#x20AC;&#x2122;s hold on current markets and be the key to new ones.

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By establishing pro-active initiatives we can make design work for our economy and start manufacturing products that will not only meet the needs of both the domestic and Sub-Saharan markets but also siphon off some of the lucrative rewards that can come from exporting value added products. Mike Wythe, industrial designer and lecturer for the Industrial Design Programme at the Tshwane University of Technology (TUT), feels passionately about helping to produce the next generation of creative industrial designers in South Africa. A graduate from the Royal College in London where he completed his postâ&#x20AC;&#x201C;grad Masters in Industrial Design Engineering, during his career Mike has moved through a diverse range of design, product development, manufacturing and management disciplines.

FEBRUARY / MARCH 2013 87

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BOOKS

Pan-European distributors expand through downturn Distributors’ polymer sales increase as suppliers revise their customer base POLYMER distribution accounted for 11% of polymer sales in Europe in 2011, equivalent to approximately 3 million tons of resin¹ and representing sales of over €6-billion. According to research recently published by AMI Consulting, despite the impact of the eurozone crisis and volatile pricing and supplies, the sector has continued to grow and increase in importance within the polymer industry supply chain with sales through distribution channels growing ahead of the overall demand for polymer. However, sales growth was markedly slower for the 2012 period, with distribution volumes running at half the rate compared to the previous two years. Furthermore, the distribution industry still has some way to go to recover the volumes lost during the 20082009 recession, with 2011 sales more than 500,000 tons lower than in 2007. AMI Consulting has been monitoring and analysing the trends in the European polymer distribution industry for over a decade and has now published the ﬁfth edition of its well established ‘Polymer Distribution Report,’ which is the result of comprehensive and extensive primary research. Polymer distribution is playing an increasingly important strategic role within the polymer industry value chain, providing opportunities for polymer producers to cut

The AMI report suggests that the role of polymer distributors is likely to expand. In the European case, distribution sales are expected to advance at double the rate of that expected for underlying polymer demand growth over the next ﬁve years. In Southern Africa the trend is likely to be similar

costs, improve efﬁciencies and deliver better service and support to the plastics processor. These trends are being further encouraged by rationalisation of the customer base by the polymer majors and the increased availability of resin from the Middle East and Asia offering potentially new distribution mandates However, distributors are also facing a number of challenges. Polymer producers often pass customers with poor credit rating onto distributors, and hence increasing their risks. Volatile market conditions with rapidly ﬂuctuating resin prices have also made forecasting of sales more challenging. Besides that, the producers increas-

ingly prefer to deal with fewer distributor groups who can offer international coverage, as opposed to dealing with many individual local players. Overall though, AMI’s view is that the trends will favour distribution with polymer suppliers channelling more material via ofﬁcial networks. As a result, distribution sales are expected to advance at double the rate of that expected for underlying polymer demand growth over the next ﬁve years. • POLYMER DISTRIBUTION IN EUROPE IS A DETAILED MULTI-CLIENT REPORT. FOR MORE INFORMATION, CONTACT KARLA VITTOVA, TEL: +44 117 924 9442, E-MAIL: KV@AMIPLASTICS.COM

Plastics proﬁt: Global market for plastic pipes

Practical guide to rubber injection moulding

THE market research institute Ceresana is forecasting total global revenues of more than US$80 million in 2019 for plastic pipes. While pipes based on PP and PE are still in the process of challenging the dominance of PVC-pipes in potable water supply, they are already playing a notable part in both gas supply and in industrial applications. Over the next few years the use of other plastics, such as polybutylene, polyamide and acrylonitrile-butadiene-styrene, is likely to become more and more widespread. Yet PVC will remain the major raw material for the pipe industry with an expected market share of more than 55%. Second most important material is PE, HDPE in particular. For this type, forecast market shares vary greatly depending on region and were between 28% and 45% in 2011. The study includes forecasts up to 2019 and examines the 16 largest countries of the market in more detail. The study provides detailed proﬁles for 76 manufacturers.

THERE are many factors that contribute to success or failure in rubber injection moulding, from the design stage of a product, through choosing and setting up machinery, to experimenting and ﬁnding the best operating conditions. Smithers Rapra Publishing has released “Practical Guide to Rubber Injection Moulding” aimed at potential customers and personnel in the injection moulding industry. The book emphasises quality control, including working to the ISO 9001 Standard. It also highlights the need to consider the economics of operation prior to taking on new projects. Above all, the customer-manufacturer relationship is emphasised at all stages. The customer is encouraged to examine the capabilities of the manufacturer, and the manufacturer is encouraged to develop a good understanding of the exact requirements of the customer.

www.ceresana.com 88 FEBRUARY / MARCH 2013

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AROUND THE WORLD Canadian group buys KraussMaffei TORONTO private equity firm Onex has completed its $732m purchase of German plastics machinery maker KraussMaffei Group. KraussMaffei employs 4,000 worldwide and had sales of almost $1.3bn in the fiscal year ended 30 June 2012. The firm had been owned since 2006 by private equity investor Madison Capital Partners of Chicago. KraussMaffei makes injection moulding machines, extruders and reaction injection molding machines at plants in Germany, Switzerland, Slovakia and China.

Treofan aims at global growth TREOFAN group of Germany, until recently the owner of what is now FIMA films, the BOPP film manufacturer in Krugersdorp, has refinanced its outstanding senior credit facility and appointed a new CEO, Peter Vanacker. One of the major changes is the appointment of a new executive committee to replace the former management team. “We wanted to bring people from other businesses, with global experience, into our business,” said Vanacker, formerly of Bayer MaterialScience.

Solvay expands silica capacity in France SOLVAY has expanded its highly dispersible silica capacity production at its Collongesau-Mont-d’Or site in France. This investment follows a similar volume expansion last year in the US and the start-up in 2010 of a new plant in China. These three investments required in total €74 million. Solvay’s worldwide highly dispersible silica production capacity now exceeds 400,000 tons. Demand for highly dispersible silica reﬂects the growing demand for safer and energy-efﬁcient tyres and the new tyre labelling legislation.

Symphony says trading losses to get worse SYMPHONY Environmental Technologies, the specialist plastics group, has warned that trading losses for its financial year ending 31 December 2012 will be ‘materially higher’ than those it predicted last month. The stock market-listed firm warned that revenues for December were “significantly less than anticipated” at the time, “and as such the trading loss for the year will be materially higher than £1.1m”. Revenues for the full financial year were down 42% at £4.9m. Symphony said £2.8m in revenue was generated in the second half, compared with £2.1m in the first six months.

FIRST U.S. STADIUM TO USE PC SHEET FOR ENTRANCE FACADE WHEN Houston’s new BBVA Compass Stadium opened this year, Houston Dynamo fans were welcomed with a brilliant display of the soccer team’s distinctive orange brand featured on enclosed entrances with a vibrant shade of Lexan™ Thermoclick™ sheet from SABIC’s Innovative Plastics business. This new, state-of-the-art, open-air stadium is the ﬁrst U.S. stadium to use PC Lexan Thermoclick sheet for its enclosed entrance facade. Enhanced design freedom and a brilliant orange colour provided by SABIC’s 50-mm Thermoclick sheet made a major contribution to the unique style of the new urban stadium. The material’s nine-

wall configuration delivers a high level of thermal insulation for energy savings, and the 1,000-mm wide panels – twice the width of traditional panels – reduced installation time and labour to support tight construction budgets. With a specially designed V-joint connection profile, including a groove and smart snap design on both sides, Lexan Thermoclick sheet’s interconnecting configuration eliminates the need for vertical profiles. The new tongue-and-groove connection design provides high stiffness and low horizontal purling at larger spans. www.sabic.com

Engel hands 1500th

machine to Lego ENGEL Austria handed over its 1500th injection moulding machine to the Lego Group at the beginning of December. Lego® elements in many shapes and colours are produced on Engel machines at the Lego sites in Denmark, Hungary and Mexico. Engel and the Lego group have enjoyed a good working relationship for over 40 years now and have driven many new developments forward together over the course of this period. Just under half of the 1500 machines supplied by Engel in the last four decades are currently in use at Lego group

factories today. One of the main contributors to the relationship is the interest of both companies in sustainability: “It is our ambition to have a positive impact on the environment,” stresses John Hansen, head of quality and engineering at Lego. “This means that, with regard to injection moulding, we invest exclusively in energyefﬁcient machines. Engel technologies are part of this.” www.engelglobal.com

World’s ﬁrst large-scale plant for bio-based succinic acid REVERDIA, the joint venture between DSM and Roquette Frères, a global producer of starch and starch-derivatives, has begun operations in Cassano Spinola, Italy, at a commercial-scale plant producing Biosuccinium™ sustainable succinic acid. The plant, which has a capacity of about 10,000 tons a year, is the world’s ﬁrst dedicated large-scale plant for the production of succinic acid from renewable resources. Key applications for Biosuccinium include PBS, polyester polyols for polyurethanes, coating and composite resins and phthalate-free plasticizers.

www.reverdia.com 90 FEBRUARY / MARCH 2013

Reverdia starts operations at the world’s ﬁrst large-scale plant for bio-based succinic acid

WORLD NEWS

Plastic bulb development

promises better quality light BY MATT MCGRATH, ENVIRONMENT CORRESPONDENT, BBC NEWS RESEARCHERS in the United States say they have developed a new type of lighting that could replace fluorescent bulbs. The new source is made from layers of plastic and is said to be more efficient while producing a better quality of flicker-free light. The scientists behind it say they believe the first units will be produced in 2013. Details of the new development have been published in the journal Organic Electronics. The new light source is called fieldinduced polymer electroluminescent (Fipel)

technology. It is made from three layers of white-emitting polymer that contain a small volume of nanomaterials that glow when electric current is passed through them. The inventor of the device, Dr David Carroll, professor of physics at Wake Forest University in North Carolina, says the new plastic lighting source can be made into any shape, and it produces a better quality of light than compact fluorescent bulbs which have become very popular in recent years. The new light source is said to be twice as efficient as fluorescent bulbs.

Wuhu Conch buys 24 extruders BATTENFELD-cincinnati has received an order for 24 extruders from Wuhu Conch Proﬁles and Science Ltd., located in Anhui/China. The powerful extruders with diameters between 63 and 93 mm and outputs ranging from 70 to 380 kg/h, have been in operation since the middle of 2012. With this expansion of its machinery and equipment, the world’s largest window proﬁle manufacturer has increased its PVC processing capacity to more than 700,000 tons per year.

www.battenfeld-cincinnati.com

SABIC commissions LNG-powered tankers Saudi Basic Industries Corporation (SABIC) has commissioned the construction of two sea-going gas tankers powered by liquified natural gas (LNG) to transport its olefins products, in anticipation of a European Union directive to drastically reduce sulphur emissions from vessels operating in the North Sea by 2015. Switching to alternative fuels for ships, such as LNG, which is more environment-friendly than traditional fuel oils, is one of the solutions identified to meet the European Union directive.

www.proﬁle.conch.cn/english/

FEBRUARY / MARCH 2013 91

Optimal solutions for medical technology

In Class 8 cleanrooms (100,000), fully automatic and manual assembly takes place, not forgetting the packaging of components and assembly units ranging from pilot/preproduction series and just-in-time produced batch sizes, right through to runs of many millions. Strategically positioned checkpoints and 3D precision metrology support the company’s stringent quality surveillance and assurance system.

Spang & Brands achieves cleanroom certification High level of EU qualifications reached for the manufacture of medical devices THE production of medical devices is subject to a number of the most stringent regulations and conditions, one of them is the DIN EN ISO 13485 certification, an indispensable prerequisite for the qualified production of complete systems, such as the mixing and dosing systems for bone cement, explains Friedrich Echterdiek, MD at Spang & Brands GmbH based in Friedrichsdorf, Germany. The company, renowned manufacturers of plastics components for medical and pharmaceutical use, reached this high level of qualification in December 2012 after almost a year of intensive preparation and appropriate reorganization. During MEDTEC from 26-28 February in Stuttgart, Germany, the company will exhibit more than 50 different medical products - component groups, precision and micro products manufactured in mono or multi-component injection moulding technology.

WITTMANN BATTENFELD will present its competence in medical technology, especially in micro technology, at Medtec in Stuttgart from 26-28 February. The electric Wittmann Battenfeld PowerSeries machines were developed to create optimal solutions for manufacturing medical technology products and implementing clean-room applications. The all-electric EcoPower and MicroPower series are the perfect choice for medical technology applications. This micro filter made of POM with an 80μ grid and a part weight of 1.1 mg, which can be used in acoustical engineering as well as in micro pumps or inhalators. The micro filter was manufactured on a MicroPower 15/10, which has been specially developed for high-precision injection moulding of small and micro parts. It is produced in a 2-cavity mould with 3-platen injection. www.wittmann-group.com Micro filter for medical technology

www.spang-brands.de

The Innovation Compass at www.k-online.de is online

Lab-on-a-chip at the Medtec Europe

Scientists highlight the trends in plastics, rubber industry AT www.k-online.de, celebrated polymer research and technology scientists are publishing keynote articles on current themes in the sector and highlighting the trends that will drive market development in the coming years. The publication of these technical articles marks the first step in emphasising the abundance of innovations at the world’s most important trade fair for the industry - K 2013 from from 16-23 October, in Düsseldorf, Germany. Exhibitors can enter their products and processes in the Innovation Compass and draw attention to specific innovations. The Innovation Compass offers a guide to classifying and tracking down innovations according to their fields of application. At K 2013 about 3,000 companies from all over the world will again introduce the trade public to their offerings in the fields of machinery and equipment for the plastics and rubber industry, raw materials and auxiliaries, and semi-finished products, technical parts and reinforced plastics. A special presentation featuring ‘Plastics first choice for winners’ will pull back the curtain on the various applications polymers have found in sport with a host of examples from the fields of competitive and recreational sports, sport for the disabled as well as sports architecture PHOTO: MESSE DUESSELDORF / TILLMANN

www.k-tradefair.com

92 FEBRUARY / MARCH 2013

ARBURG will be exhibiting a high-end application at this year’s Medtec Europe in Stuttgart between 26-28 February. The electric Allrounder 370 A with a clamping force of 600 kN and size 70 injection unit will operate with a two-cavity mould from z-microsystems. This company produces customer-speciﬁc medical components for use in analysis and diagnostics (lab-on-a-chip and microﬂuidics). Z-microsystems specialises in the production of prototypes in the development phase, through to small- and large-scale production. So-called bottom layers for a lab-on-chip application will be produced as demonstration parts. The lab-on-a-chip will be completed with a top layer containing its own microchip for transporting liquids and displaying results. (PHOTO: Z-MICROSYSTEMS)

www.arburg.com

2013 EVENTS JEC EUROPE 2013

MOVING forward to the 27th edition, CHINAPLAS not only continues to hit the new record on the show scale, but also brings in many new elements. In order to allow visitors to have sufficient time for procurement and technological exchange, the show period of CHINAPLAS 2013 will be extended to four days from 20-23 May at China Import & Export Fair Complex, Pazhou, Guangzhou, China. In view of the extensive application of plastic film and its technology nowadays, a ‘Film Technology Zone’ will be established to cater for the increasing needs of plastic film buyers from the medical, electronics, I.T., solar power, packaging and building industries. This zone will showcase a wide range of exhibits which include extrusion lines for blown film, flat film and sheets, stretching lines for film and filament, slitter rewinders, winding equipment, measuring & testing equipment for film, auxiliary equipment for film extrusion lines, printing machines for film, lamination and coating machines and other film processing technologies. The organisers will also increase the size of ‘Die & Mould Zone’ by 18% over the last edition. Two specialized regions will be established under the ‘Chemicals & Raw Materials Zone’ - they are ‘Color Pigment & Masterbatch Zone’ and ‘Additive Zone’. www.ChinaplasOnline.com

AfriMold 2013 Earlier date and new venue AFTER evaluating last year’s AfriMold, extensive strategizing and consideration of the industry’s feedback and requests, the organisers have introduced a new date and venue for AfriMold 2013. AfriMold 2013 will now take place from 4-6 June at the NASREC Exhibition Centre in Johannesburg. Moving the trade fair earlier in the year will present exhibitors and visitors with better and stronger opportunities to secure sales and generate leads, along with the much needed extra time to convert these into solid, secured business before the industry winds down for the year.

The NASREC Exhibition Centre is host to several industrial expos and as a result has the facilities to accommodate AfriMold’s needs, including the capacity for loading heavy machinery. This new venue will greatly increase your ability to showcase and demonstrate your products, services and solutions to maximum effect. CONTACT TERRI BERNSTEIN ON 083 635 3539 OR EMAIL TERRI@AFRIMOLD.CO.ZA; ANN EVANS ON 082 336 6791 OR EMAIL ANN@AFRIMOLD.CO.ZA TO SECURE YOUR POSITION AT AFRIMOLD 2013.

PVC FORMULATION MARKET trends and technical developments in PVC additives and compounding will be showcased from 12-14 March, Hilton, Düsseldorf, Germany, at the 5th edition of the PVC Formulation conference. The event attracts over 300 attendees from across the world involved in all aspects of the PVC formulation industry – from PVC producer and raw material supplier to equipment manufacturer. www.amiplastics.com

PLASTICS IN AUTOMOTIVE ENGINEERING THE international VDI conference Plastics in Automotive Engineering in Mannheim, Germany, from 13-14 March takes the form of technical lectures as a comprehensive overview of innovative solutions in the development of materials and processing technology in the plastic speciﬁc area. Renowned specialists of the vehicle manufacturers Audi, BMW, Daimler, Evobus, Ford, MAN, Opel, Porsche, Renault and VW will introduce current component innovations for the automotive industry design clear progress on the issues of energy and weight efﬁciency, safety, functionality and and comfort. www.kunststoffe-im-auto.de

INTERNATIONAL RUBBER CONFERENCE THE next International Rubber Conference uniting the entire rubber and polymer industry will take place from 20-22 March in Paris (Palais des Congrès Porte Maillot), organised by the AFICEP under the aegis of the IRCO. There will also be some 84 oral presentations and 30 posters will also be presented during the programme. Speakers from across the world will lead debates divided into ﬁve themes: Chemical aspects and formula ingredients; Manufacturing processes and optimising procedures; Eco-design and end of life recovers, safety, health, and the environmentl; Innovation in rubber product design and uses; Prospects and perspectives for the Rubber industry. www.irc2013.com

FEBRUARY / MARCH 2013 93

DIARY

Plenty new elements at CHINAPLAS 2013

THE composite industry’s largest international technological showcase, JEC Europe – Composites Show & Conferences, takes place from 12-14 March at the Paris Porte de Versailles. Twelve key themes will be highlighted during the 3-days trade show: Design, non-destructive testing, robotics, aeronautics, automotive, E-car, wind power, carbon, biocomposites, thermoplastics, multifunctional materials and environment. With 50,000m2 of ﬂoor space, the JEC Show will represent the global composites industry’s most recent advances in heavily composite-consuming sectors such as aerospace, aeronautics, shipbuilding, railway, automotive, mass transportation, construction, equipment and sports & leisure. www.jeccomposites.com/events/jec-europe-2013

More than 55 000 PIPELINE COATING 2013: 18-20 February Austria Trend Hotel Savoyen, Vienna: www.amiplastics.com/events WOOD-PLASTIC COMPOSITE CONFERENCE: 26-27 February Vienna, Austria: www.amiplastics.com/events MEDTEC EUROPE: 26-28 February: Stuttgart, Germany: www.events.ubm.com DESIGN INDABA: 01-03 March: CTICC, Cape Town: www.designindaba.com SOUTHERN AFRICA OIL, GAS & ENERGY: 05 March Sandton Convention Centre, Johannesburg: www.petro21.com AFRICA ECONOMIC SUMMIT: 06 March Sandton Convention Centre, Johannesburg: www.petro21.com 8TH ‘ADDITIVES & COLORS’ CONFERENCE: 06-07 March Königswinter (Bonn), Germany: www.speeurope.org 19TH MEDICAL FAIR INDIA: 08-10 March Pragati Maidan, New Delhi: www.medicalfair-india.com JEC EUROPE: 12-14 March: Paris, France: www.jeccomposites.com PVC FORMULATION 2013: 12-14 March Hilton Hotel, Düsseldorf, Germany: www.amiplastics.com

visit EuroMold 2012 EUROMOLD 2012 closed successfully on 30 November with 55 965 visitors from 92 countries. Most of the visitors came from the automotive industry followed by engineering, medical industry, electrical-and electronic industry. A visitor increase was noticed from home appliance industry and toy industry. In total 1 086 exhibitors from 35 countries showed their products and services. With 145 speakers EuroMold offered the largest forum and conferences since its creation 19 years ago and yet again proved its unique direction for information, education and innovation. www.euromold.demat.com

PROPAK AFRICA: 12-15 March: Nasrec, Johannesburg: www.propakafrica.co.za PLASTICS|SA CONFERENCE: 13-14 March Nasrec, Johannesburg: www.plasticssa.co.za PLASTICS IN AUTOMOTIVE ENGINEERING: 13-14 March Mannheim, Germany: www.kunststoffe-im-auto.de ARBURG TECHNOLOGY DAYS 2013: 13-16 March Lossburg, Germany: www.arburg.com GREEN POLYMER CHEMISTRY 2013: 19-21 March Maritim Hotel, Cologne, Germany: www.amiplastics.com/events

DIARY

TYREEXPO ASIA 2013: 19-21 March Singapore Expo Centre, Singapore: www.eci-international.com INT’L RUBBER CONFERENCE: 20-22 March: Paris, France: www.irc2013.com TIPREX 2013: 03-06 April: BITEC, Bangkok: www.tiprex.com PIPES IN INFRASTRUCTURE 2013: 09-11 April Hotel Nikko, Dusseldorf, Germany: www.amiplastics.com/events ANTEC 2013: 22-24 April: Cincinnati, Ohio, USA: www.antec.ws AUTOMECHANIKA JOHANNESBURG: 08-11 May Nasrec (Johannesburg Expo Centre): www.automechanikasa.co.za RAPID TECH 2013: 14-15 May: Erfurt, Germany: www.rapidtech.de AFRIPLAST EXPO: 14-16 May Gallagher Convention Centre, Midrand: www.exhibitionsafrica.com CHINAPLAS 2013: 20-23 May Pazhou, Guangzhou, PR China: www.ChinaplasOnline.com FUTURE TYRE 2013: 04-05 June: Brussels, Belgium: www.tyre-conferences.com AFRIMOLD 2013: 04-06 June Expo Centre, Nasrec, Johannesburg: www.afrimold.co.za AFRICARAIL 2013: 24-26 June Sandton Convention Centre, Johannesburg: www.events-africa.com PPS-29 (POLYMER PROCESSING SOCIETY) INT’L CONFERENCE: 15-19 July Nuremberg, Germany: www.pps-29.com KZN INDUSTRIAL TECHNOLOGY SHOW: 23-26 July Durban Exhibition Centre: www.kznindustrial.co.za DRINKTEC: 16-20 September: Munich, Germany: www.drinktec.com POLYURETHANES TECHNICAL CONF: 23-25 September Phoenix, Arizona: www.polyurethane.americanchemistry.com MEDIPLAS 2013: 25-26 September NEC, Birmingham, UK: www.meetbirmingham.com TUBOTECH 2013: 01-03 October Sao Paulo, Brazil: wynhoffU@messe-duesseldorf.de K2013: 16-23 October: Düsseldorf, Germany: www.konline.de WIND TURBINE BLADE MANUFACTURE: 03-05 December Maritim Hotel, Dusseldorf, Germany: www.amiplastics.com/events EUROMOLD 2013: 03-06 December Exhibition Cenre, Frankfurt, Germany: www.euromold.com 94 FEBRUARY / MARCH 2013

Portuguese injection moulder at Afriplast PORTUGAL-based Geco, a manufacturer of plastic injection moulding machinery, is one of several overseas exhibitors taking part in Afriplast Expo 2013, South Africa’s inaugural international plastics industry trade fair, at Gallagher Convention Centre from 14-16 May. Geco operates a 16 000m2 production plant in Maceira with a staff of over 300 people, and has ofﬁces in six countries. The company specialises in the manufacture of injection moulds for thermoplastic, thermo-resin, twocomponent and gas-assisted injection moulding and supplies numerous markets including the automotive, electrical, packaging, media, pharmaceutical and household product sectors. “Our South African market share has grown steadily and now represents 5% of total sales. We are now also considering expansion into Sub-Saharan Africa. We are using the expo to promote the company and its products in the region, and use market feedback to ascertain if South Africa would be a viable market for establishing a production plant,” said Jorge Jorge, the company’s commercial director. Geco will be showcasing its latest innovation at the Afriplast Expo, the new MuCell system combined with a Sandretto 3500 ton injection moulding machine. Afriplast 2013 is a new plastics industry trade event that forms part of the recently-introduced South African Industry and Technology Fair (INDUTEC). www.exhibitionsafrica.com GECO Headquarters in Portugal

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SPORTS

Marathon on ice

Ice dice – Harry Botha, 71, was in ﬁne shape for the 42km Ice Marathon in Antarctica, where part of the challenge was managing the glare off the snow and ice – a big problem as the sun shines for 24 hours a day at the height of summer

‘Race’ became secondary to appreciating incredible beauty of untouched white wonderland

CASUAL jogger turned marathon man Harry Botha recently completed the ‘Ice Marathon’ in Antarctica – a formidable challenge which formed the fourth ‘leg’ of his quest to run a marathon on each of the seven continents.

Formerly of TerBo Plastics# of Krugersdorp, Harry retired in 2006 and moved with his wife to Ballito on the KZN North Coast, where they have a house overlooking the sea – “almost every Vaalie’s dream,” said Harry. After joining the local running club, he went from being a casual jogger to training more seriously and soon ran his ﬁrst race of 16kms, which in turn led to a half marathon. After that he ran the Berlin marathon, joining a former training partner who had been transferred to Germany. “In order to keep training, I needed a goal and started looking for another International marathon. I decided on London 2009, and later that year ran the New York City marathon,” said Harry. After that he ran the Boston Marathon, followed later that year by the Chicago Marathon, so completing the so-called ‘World Marathon Majors’ – (Berlin, London, New York, Boston and Chicago) – by the end of 2010. The next challenge was to run a marathon on each of the seven continents, which led him to the ‘Ice’ event. A big part of the challenge was simply to get there in 96 FEBRUARY / MARCH 2013

the first place: after months of preparation, Harry joined a group of 61 adventurers from all over the world at Punta Arenas in Chile, the departure point for the flight to Antarctica on November 19 last year. Eleven of the adventurers weren’t content with just the 42km marathon, and embarked on the epic 100km version of the race. Harry very cleverly decided on the ‘shorter’ option. After a rigorous inspection of their gear by race officials, they were flown to the glacier camp at the foot of the Ellsworth Mountains in Antarctica, where the race was run at an elevation of about 700m. “The marathon became secondary to being on this pristine ice covered continent one-and-a-half times the size of the USA. Being on a 12,000-year-old glacier 1000 metres thick is an experience I won’t forget,” said Harry. The runners had to contend with 24 hours of sunlight so bright that sunglasses were required all the time when outside. “The marathon took place in clear weather, temperature was around minus 20ºC – but being adequately dressed I hardly felt the cold. For the most part it was like running on loose beach sand, which meant hard work and resulted in a time of 7 hrs and 13 minutes – compared to a normal road marathon time of sub-5 hours. “To run in these conditions and not develop frostbite or hypothermia, we were required to wear woolen socks, gloves and mittens, a layer of thermal underwear,

There was no stopping Harry on the day

a ﬂeece and an outer wind-proof garment. Still, on the ﬁrst night I was wearing three pairs of socks and my feet were frozen,” he added. “There were two very serious runners, Andrew Murray of Britain, who went on to win, and Luis Alonso Marcos of Spain, who was close at his heels. But for the rest of us it was a case of pacing yourself and just getting to the next water table, where they gave us hot water to prevent it turning into ice!” Well done Harry! Note: # TerBo Plastics was later purchased by Transpaco group, of which Harry is in fact still a non-executive director.

www.icemarathon.com

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We lead... others follow National Sales Number: +27 11 902 8923 FAX: +27 11 902 8980 email: jhb@plasquip.co.za www.plasquip.co.za Please call for your local costal representative details and office number