S a plastics '014 02 (web)

CREATIVE MATERIALS FOR CREATIVE IDEAS

BY THE WAY ...

You don’t get involved in recycling to make a quick buck 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: Jeanette Erasmus Graphic Design (jeanette.erasmus@lateraldynamics.co.za) 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

IN THE last issue we published an article about the new Enviroserv tyre recycling plant in Cape Town. Enviroserv is one of the top multi-material recycling businesses in South Africa which has been “partnering with organisations looking for best practice sustainable waste solutions� for over three decades.

As many of us know, tyre recycling

About 10 James Parks of Victoria International of million tyres Durban, a supplier of a range of materials enter waste itself (including plastic and rubber materials), wrote and summarised the stream a year

in SA tyres, of which there are a LOT – about 10 million tyres enter the waste stream a year in South Africa.

Parks noted that the energy and transport costs are high, and would probably amount to about 70% of the total cost. Another hazard is the

Peter Waldburger of Enviroserv thanked James for his summary and said Enviroserv (which has proven that it can manage the logistics aspect of recycling process streams) could adequately deal with the transport issues, in terms of the Waste Act and REDISA initiative. He added: “The only comment I can make is that no one goes into any

Tragic setback for leopard conservation man IN OUR last issue we reported optimistically about the leopard conservation programme embarked on by industry veteran Bob Boden of Johannesburg, who’s been hard at work trying to capture leopards on camera. Working near Broederstroom and Hartbeespoort in the Witwatersberg hills, Bob had as yet had no success with his camera ‘traps’. Very sadly, poachers were successful. On the night of 14 January at Hartbeeshoek, about 20kms west of the study area,

!

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& restriction. Bob and his team were deeply traumatized by the tragedy, but the number of people who came out in support of their work and the conservation programme has created hope. Keep up the good ' *

Massive PVC reservoir was not made in SA IN OUR August/September 2013 issue we published an article â&#x20AC;&#x2DC;Two ;<=>

?QY Z#$ stated that the PVC-lined tank was installed in SA. The installation was done by Steelfab with whom Steelfab Water Solutions Africa have a joint venture, but not in South Africa as mentioned.

The tank was installed by Steelfab Water Solutions Asia in Subic Bay in the Philippines. The technology and capability for an installation like this is available in South Africa through the joint venture between Steelfab Water Solutions Africa and Steelfab Water Solutions Asia.

Plastics Institute

www.Steelfab.com.au

Association of Rotational Moulders of South Africa

of Southern Africa

www.sinvacplastics.co.za Plastics Converters Association

PET Plastic Recycling

Plastics Federation

South Africa

of SA

Institute of Materials

METHING HAVE SO â&#x20AC;Ś IF YOU TO SAY de: if you e bright si Look at th isdom to w e gem of at have som rite to us w se ea impart, pl ica.com fr ia s@ saplastic

VOLUME 12 NR 1

FEBRUARY / MARCH 2014

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

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

INDUSTRY NEWS Sasol inaugurates plant to boost polyethylene production

6

Type 90 Smart

Massive bag machine from Technimac

8

Temperature control units for water up to 90°C

West African Group buys Frontier

10

Seecor goes on its own

12

Habitat expands, opens mould service centre

16

Zico, ?

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18

19

34

ASSOCIATION NEWS 3

IOM ^ _ `

28

SAPPMA signs cooperation agreement with SAICE

30

PETCO international recycling colloquium sets stage for global partnerships

32

60

Design critical to growth of viable product manufacturing sector in SA

70

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

SPORTS EPDM â&#x20AC;&#x2DC;wingsâ&#x20AC;&#x2122; for joggers

s #LEAR ARRANGEMENT OF OPERATING AND indicating elements

92

84 ON THE COVER

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PU5

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unit â&#x20AC;&#x201C; a R1.9-billion venture which will enable it produce an additional 47,000 tons of polyethylene a year â&#x20AC;&#x201C; at Sasolburg in January. The EPU5 plant has been in operation since mid-October and is expected to reach its nameplate capacity by 2017. Located at the Sasol Polymers Plant in Sasolburg, the R1.9-billion ethylene

for polyethylene. The plant will also ensure better use of Sasolâ&#x20AC;&#x2122;s existing downstream polyethylene facilities. The plant took 4.6 million man-hours to build. At the peak of production, more than 1000 workers were on site.

See page 6-7 for more.

www.sasol.com

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46

DESIGN

Type 150 Smart Temperature control units for oil up to 150°C

COMPOSITES JEC Europe Innovation Awards programme

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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

Sasol EPU5 plant is seriously impressive Energy group has achieved a lot at Sasolburg WAS PRIVILEGED recently to be a guest of Sasol Polymers at the launch of the Sasol Y { ; | }{;|~Y$ ?

COMMENT

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For anyone involved in the polymer or chemicals business in South Africa, as well as Africa for that matter, ? Y

the plant before, which is disappointing for a person whoâ&#x20AC;&#x2122;s been in the industry for over 20 years, but perhaps the

Together with a group of delegates, I was fortunate to be bussed from â&#x20AC;&#x2DC;Joziâ&#x20AC;&#x2122; down to the plant on 14 January, giving

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impressive things: the plant is massive (even by global

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Obviously the Sasol people were on their best behaviour on the day, but it was good to be able to meet and talk with so many of them, plus the Sasol groupâ&#x20AC;&#x2122;s CEO David Constable and Sasol Polymers MD Marinus Sieberhagen

And Minister of Trade & Industry Rob Davies hit the right notes too, mentioning â&#x20AC;&#x201C; thankfully â&#x20AC;&#x201C; that the government

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Â&#x201A; State was looking at developing some advantage from the regionâ&#x20AC;&#x2122;s mineral resources, possibly at a price advantage,

By the way, this may not have gone down that well with ? * Â&#x192; Z Â&#x201E;> {;|~ plant alone!

EPU5 launch â&#x20AC;&#x201C; Marinus Sieberhagen, the managing director of Sasol Polymers, welcomed dignitaries and guests at the launch of the groupâ&#x20AC;&#x2122;s Ethylene "

# $ Sasolburg in January

The dismal performance of the rand since late last year has resulted in polymer prices increasing by, in some * #Â&#x2021; ?

the devalued rand will create opportunities for exports, and to an extent offset the high rate of imports, but the problem > ^ similar rate, and our customers continue to resist price Â&#x2030; Y * ##Â&#x160; Â&#x2039; Y

The other problem with the rapid rate of change is that

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Nevertheless, although there is and will be an attrition rate, many of the manufacturers in the industry have and are showing resilience and { * Polymer owners and managers canâ&#x20AC;&#x2122;t allow the prices

One possible plus at present is the increasing in reduced level of labour union activity some case

Â&#x201A; by more than problem in the mining sector, and a 20% return to the problems of 2011/12 would

Obviously young people want to improve themselves, and visualising better income is a reality, but unchecked strike action can undermine businesses and even entire

On the plus side, we look in this issue at several notable

Â&#x152; done guys!

Letâ&#x20AC;&#x2122;s try and keep our cool and get the job done this

Itâ&#x20AC;&#x2122;s going to be tough Â&#x2020;|?Â&#x201A; #Â&#x2021;ZÂ&#x2C6; Y

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4 FEBRUARY / MARCH 2014

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Sasol inaugurates plant to boost polyethylene production Plant is expected to reach full capacity by 2017 SASOL unveiled its new EPU5

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9

INDUSTRY NEWS

West African Group buys Frontier WAG expands service to rubber and tyre market WEST AFRICAN Group (WAG) has expanded its materials portfolio for the rubber and tyre markets through its recent purchase of Frontier Industries (FI).

As one of South Africaâ&#x20AC;&#x2122;s top suppliers of rubber-related raw materials, processing aids and additives, FI was established in 1981 in Durban by John Everitt. FI supplies both natural and synthetic rubber grades as well as a comprehensive range of processing aids and rubber/plasticrelated raw materials and chemicals; it supplies the tyre and rubber/plastic industrial sectors across southern Africa.

WAG, set up by Jack Doherty in 1992, also in Durban, has due to the strategy adopted over the past two decades become a far larger entity with regional

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various natural and synthetic rubber grades, WAG also supplies a range of strategic polymers and other materials.

Frontier enjoys a good reputation in 10

FEBRUARY / MARCH 2014

West African Groupâ&#x20AC;&#x2122;s Jack Doherty (left) and Frontier Industriesâ&#x20AC;&#x2122; John Everitt: WAG has purchased FI and will continue to supply the materials it provides and plans to expand the service

the marketplace, dating back to the time of Johnâ&#x20AC;&#x2122;s father, the late Ray Everitt. Cofounder of the erstwhile Lewis & Everitt ZÂ&#x201E;Â&#x2C6;Â?*

material supply businesses in South Africa.

With the market having changed

* viability of smaller operations supplying a national Industry has been tested.

Prices for raw materials have increased

have proved risky, with smaller operations at times being exposed in the process. â&#x20AC;&#x153;It will certainly be more suitable to supply the FI range on a national basis, in which respect WAG has greater resources and a far wider area of established representation and technical expertise,â&#x20AC;? he added.

Doherty said some of the processing aids and other specialist materials supplied by FI are complimentary to the NR/SR materials that WAG offers and the tie-up hence offers >

FI will run as a fully-owned subsidiary of WAG, operating out of the groupâ&#x20AC;&#x2122;s

] * Â&#x2022; Q > serving FI secretary/PA Leslie Ogle, John will remain involved, but he will operate as an independent consultant with a renewable annual consultancy agreement Â&#x2013;

Umgeni Park, Durban North. www.westafricangroup.co.za

â&#x20AC;&#x2122; e c i v r e S l a n o s â&#x20AC;&#x2DC;A Per

INDUSTRY NEWS

Seecor goes on its own, JV with Maritime ends Top blow moulding marques now represented by SA machine â&#x20AC;&#x2DC;rebuilderâ&#x20AC;&#x2122; SEECOR Blow Molders and Maritime Marketing have terminated their cooperation arrangement by mutual consent. The companies entered into a marketing and technical cooperation agreement in 2010 but decided to end the deal late last year.

Seecor is South Africaâ&#x20AC;&#x2122;s leading manufacturer and supplier of blow moulding machinery. One of the sequels to the scenario is that two of the Maritime groupâ&#x20AC;&#x2122;s blow moulding specialists, John Craw and Joe Spohr, have now joined Seecor. The advantage for Cape Town-based Seecor is that it now gains direct representation in Johannesburg and Durban, through Craw and Spohr respectively.

Clive Corder and Darrin Botha head Seecor, based at the companyâ&#x20AC;&#x2122;s machine building centre in Viking Business Park,

Epping, Cape Town, where it â&#x20AC;&#x2DC;rebuildsâ&#x20AC;&#x2122; blow moulding equipment.

Backed up by a full contingent of service and technical personnel, Seecor continues to supply the very popular SIKA extrusion blow moulding machines, built in Taiwan, but it will from now also supply machines from Urola, Keli and Magic, agencies which have been brought on board by Craw and Spohr.

KELI, of China, is a manufacturer of injection blow moulding machines.

Magic, of Italy, is a top international builder of extrusion blow moulding equipment.

The Urola rotary-wheel extrusion blow moulders for high-speed mono- and multilayer bottle production, as well as re-heat PET equipment from 2-8 linear cavities, are built in Spain. Urola also supplies moulds.

â&#x20AC;&#x153;Seecorâ&#x20AC;&#x2122;s rebuild and remanufacturing business is going strong, focusing on shuttle and small-wheel rebuilds,â&#x20AC;? said Corder. â&#x20AC;&#x153;We also supply complete control and automation services, machinery maintenance and up-keep programmes, as well as a full range of material handling and granulator machinery. â&#x20AC;&#x153;We now focus on the entire African market â&#x20AC;&#x201C; we have been involved in Â&#x192;

Â&#x203A; * \ * Â&#x203A; * ` * Â&#x161; sub-Saharan areas, plus Israel,â&#x20AC;? said Corder.

Seecor will continue to cooperate with Maritime when turnkey systems are required, such as for injection moulding and recycling, he added. www.seecor.co.za

Owner-managed businesses can take it to the next level with the right â&#x20AC;&#x2DC;coachingâ&#x20AC;&#x2122; Most of use have skills in some areas â&#x20AC;Ś and a lack of skills in others â&#x20AC;&#x201C; but solutions that work for you are achievable THE challenges for SMEs are enormous, from red tape to access to market.

However, one of the biggest problems for entrepreneurs is that they usually have huge passion and skill in one area of the business â&#x20AC;Ś and a lack of skill or

* * sales, and team management).

As a result they may be overwhelmed by the admin, work longer hours than they ever imagined as an employee,

& * to delegate work, are trying to compete on price and try to be everything to everyone.

It used to be said that over 60% of all start-up businesses would fail in the

Â&#x201C; Â&#x2C6;Â&#x160; of start-ups make it to 10 years. In the meantime big business is downsizing and EMEs now employ more than 60% of the South African workforce. The economy is relying on small business 12

FEBRUARY / MARCH 2014

for growth. This year, Rob Davies, Minister of Trade and Industry reported that the business failure rate has worsened to 71%.

Margaret Fry, well-known to the plastics and packaging industry after more than two decades in technical service, product development, key account management and business Q{= * ; * ? and Huhtamaki, has established a new venture, ActionCOACH, which provides guidance to owner-managed businesses

! â&#x20AC;&#x153;As a business coach I want to help business owners to grow their business.

My aim to work with business owners so that running their business becomes fun again. Together we identify new business leads, improve turnover, improve

*

Â&#x152; strategy and goal setting, to take the

ActionCOACH â&#x20AC;&#x201C; Margaret Fry has strategies that could help you make running your business fun again

business to the next level. Our aim is *

enterprise that works without you.

This will give you the freedom to take holidays, have a succession plan and a

! * ! Â&#x201D;Â&#x152; *

something to do that would give back, doing things I am passionate about and using my skills and education. I was already coaching MBA students at Wits Business School and candidates in the Cape Wine Master programme, so when I founded ActionCOACH, it provided another opportunity to do something in that line. Itâ&#x20AC;&#x2122;s fascinating to challenge people out of their comfort zone and to expose them to the self-limiting beliefs that are holding them and the business back.â&#x20AC;? www.actioncoach.com

INDUSTRY NEWS

SABIC now warehousing in Cape Saudi group improves supply to local market SABIC group has expanded its footprint in South Africa with the opening of a warehouse in Cape Town.

The Saudi Arabian materials manufacturer decided in 2007 to introduce storage facilities in South Africa and

in the country in Durban, to supply the Gauteng and KZN markets.

The Cape warehouse in Montague Gardens, opened late last year, will be

materials as well as PET and PVC grades for converters in the Western and Eastern Cape which will greatly improve logistical

This is an important step for SABIC group as it strengthens its position in the local market and improves customer service levels, especially as regards supply reliability and delivery lead times.

SABIC South Africa director Dr Antonie Potgieter said the decision to warehouse material in Cape Town was aimed at improving the groupâ&#x20AC;&#x2122;s service offering to customers in Cape Town, Port Elizabeth

Waseem Abdulla and Antonie Potgieter, sales manager for polymers and managing director of SABIC South Africa respectively, with Sipho Manjenjalo of FreightMax at the warehouse in Montague Gardens

and surrounding areas. Sub-Saharan Africa is a key and strategic market for not only SABICâ&#x20AC;&#x2122;s polymer products, but also for its wide range of chemicals, specialty chemicals and fertilizer products, he added.

Waseem Abdulla, acting sales manager

for polymers at SABIC SA, said initial market reaction to the improved Cape

stocks had moved rapidly. www.sabic.com

Best of the West â&#x20AC;Ś in the East ! pressing businesses prior to the founding WHEN a well-known local household \\ * Q Â

appliance manufacturer approached a mould to be able to produce components Miracle Mould International with a request with repeatable accuracy and quality, to â&#x20AC;&#x153;design and manufacture a new kettle the rigidity, build proportions and quality requiring minimum post-moulding assembly of a mould is crucial. This cannot be of components,â&#x20AC;? MMI accepted the more evident than when viewing the challenge without hesitation. moulds in operation and comparing MMI, Brian Almanzaâ&#x20AC;&#x2122;s company in them to similar moulds, while running.

Durban, chose a product designer to work Hot job â&#x20AC;&#x201C; To all intents and purposes, the new â&#x20AC;&#x153;This project has become something with and guided the designer through kettles appear very similar to those available on of a conversation topic with visitors to the the design phase. The end result was a the market, but the big positive from the Miracle plant,â&#x20AC;? said Almanza, in Durban after a cordless kettle which can be assembled Mould project was that a minimum of postrecent visit to China. with minimum post-moulding work, and moulding work is required, and the production â&#x20AC;&#x153;When purchasing a mould from which is practical from both a moulding and of the moulds was easier Eastern companies, it should be taken mould manufacture point view. ] !

* & into account that, yes, you can get cheaper moulds, but you will always only get what you pay for. analysis was conducted and a team of experienced MMI engineers â&#x20AC;&#x153;MMi prides itself as being the best of the West in the East! MMI was assigned to design the suite of moulds. The moulds provided * *

interesting challenges, particularly regarding core extraction and â&#x20AC;&#x153;This is achieved by careful design and an effective and post-moulding shrinkage. While the handle was moulded with cores continuous benchmarking system coupled with comprehensive extracted on a radius that was actuated with a hydraulically driven and analytical project management, assisted and made possible rack-and-pinion system, post-moulding shrinkage was predicted by by carefully chosen colleagues and partners,â&#x20AC;? said Almanza, who sequential mould completion and shrinkage measurement which is involved in mould production in South Africa as well as in China, allowed accurate measurement of the shrinkage direction and the depending on the needs of the project. extent of shrinkage of the mating surfaces.

Having run successful plastic injection moulding and metal Brian Almanza, +27 82 821 4775 www.miraclemould.com 14

FEBRUARY / MARCH 2014

SABICâ&#x20AC;&#x2122;s products touch the lives of millions of people around the world.

The company works closely with its customers to achieve their commercial ambitions and provides the right level of support to meet their manufacturing challenges.

SABIC offers its customers a wide range of polymer products such as LLDPE, HDPE, Bimodal HDPE, LDPE, PET and EPVC. SABIC South Africa (Pty) Ltd 18th Floor, Metropolitan Centre, 7 Walter Sisulu (Coen Steytler) Avenue, Cape Town, 8001 Tel: +27 21 409 6100 Fax: +27 21 409 6101

www.sabic.com

INDUSTRY NEWS

Habitat expands, opens mould service centre

Making a Habitat of it! â&#x20AC;&#x201C; Donovan Barnes of Habitat Industries and Cornelius Bezuidenhout, who is running the Habitat Mould Services business nearby in Killarney Gardens, which handles mould refurbishing (see below), repairs and ultrasonic cleaning of moulds, plus other services

HABITAT Industries, one of South Africaâ&#x20AC;&#x2122;s top blow mould manufacturers, has opened a new business, Habitat Mould Services, where it is handling mould refurbishing, repairs and ultrasonic cleaning of moulds, plus other services.

Habitat MD Donovan Barnes found that production at the main mould manufacturing plant in Killarney Gardens, Cape Town, was being interrupted by requests from convertors to refurb or service moulds, so â&#x20AC;&#x201C; when premises nearby became available â&#x20AC;&#x201C; decided to hive off these activities.

A substantial investment has been made in the new plant, with facilities including CNC mills and lathes, ultrasonic cleaning equipment and baths as well as a 3D printing system for the development of prototypes. The plant became operational in March 2012 and is now running sevendays-a-week.

Cornelius Bezuidenhout (ex-Rage Tool & Die, Bowler) was strategically planned into the system and made managing director of HMS, which

has helped make the strategy feasible, said Barnes.

Habitat Mould Services also offers laser welding, which enables it to repair split-line and other wear related problems in moulds, minimising the cost of re-manufacturing cores and components.

The opening of the Mould ?

to Habitat Industries, creating more â&#x20AC;&#x2DC;timeâ&#x20AC;&#x2122; for its main mould manufacturing operation and

more moulds at the main plant.

Barnes has been running Habitat Industries since 2002 (he worked at the company from 1995, left and joined another mould maker and then returned to Habitat, and ultimately purchased it from the previous owner). The company builds blow moulds for most of South Africaâ&#x20AC;&#x2122;s top container manufacturing businesses, for both extrusion-blow moulding, injectionstretch blow moulding (for PET bottles) and injection-blow moulding (mainly for PP jars). www.habitatindustries.co.za

Emeraude group in Cape clean-up International polymers and chemicals supplier Emeraude held its annual sales meeting in Cape Town in December, a move wisely and timeously coordinated

by Emeraude SA manager Trevor Moroney. On one of the afternoons the sales team took part in their own beach clean-up on Milnerton Beach and, even though the Cape Town council had already been to clean the beach earlier in the day, they managed to collect a fair amount of waste, as can be seen. That

gesture by the French groupâ&#x20AC;&#x2122;s team â&#x20AC;&#x201C; well done!

www.emeraude-international.com 16

FEBRUARY / MARCH 2014

SUN ACE South Africa (Pty) Ltd 12 Innes Road, Jet Park 1459, East Rand Johannesburg GPS: S26° 09.957’ E028° 12.610’

CONTACT US P.O. Box 1070, Kempton Park, 1620 Johannesburg, South Africa Tel : +27(11) 552 6200 Fax : +27(11) 552 6499 Email : info@sunace.co.za

The World’s leading producers of PVC additives and metallic stearates www.sunace.co.za

RARE Holdings invest in pipe manufacturing plant Some pipe capacity lost in the First Tech fallout is re-entering the market RARE Holdings has purchased the assets of an HDPE pipe extrusion business at Meyerton near Vereeniging and commenced production, marking its entry to the plastic pipe manufacturing sector.

The plant was formerly run by the First Tech group company Flexicon, of Witbank, but ceased production after the First Tech implosion last year.

In a R30.9-million investment, RARE purchased the production assets and structured the business to recommence

production. It has employed Tony Dean, formerly MD of Flo-Tek Pipe, Tanks & Irrigation of Olifantsfontein, to run the plant.

The development effectively means that some of the pipe capacity lost in the First Tech fallout â&#x20AC;&#x201C; when both the First Tech group companies involved in the sector, Flexicon and Gazelle Plastics, shut doors â&#x20AC;&#x201C; is re-entering the market.

RARE is a distributor and service provider of piping and related products &

cycle. It evolved through management buyout and acquisitions from a specialist pipe supplier in 1975 through to the listed entity, RARE Holdings in 2007 and ultimately the current B-BBEE-accredited and transformed RARE Group.

This deal includes the acquisition * !

in Meyerton, which will enable the company to manufacture HDPE pipe up to 1000mm in diameter for the mining, infrastructure, agricultural and industrial Â&#x201A; Q {Y

acquisition

MCG gains access to Schoellerâ&#x20AC;&#x2122;s global product range and R+D

ZICO, a leading privately-held investment company, together ? ; { * >

Â&#x2020;?{>

? _ * Â in MCG Industries.

Q > ? * Â&#x203A;

in the business. MCG is a market leader in the manufacture of injection moulded products, particularly crates, servicing customers in the beer, soft drinks, agricultural, dairy, bread and poultry industries. It operates manufacturing plants in Â&#x2020; = Â&#x201A; â&#x20AC;&#x153;MCG is a solid business with strong market position. This acquisition presents us a solid platform on which we would seek to bolt on other synergistic businesses. Additionally; we are

? ; Equity, our partner in the business,â&#x20AC;? said Zico CEO Tshego Sefolo. Â&#x201A; \=]* in operation since 1956: the company is currently involved in a growth phase, including product expansion, made possible through a licence agreement with Schoeller Arca Systems of Germany, one of the largest global manufacturers of injection moulds. The agreement gives MCG access to Schoellerâ&#x20AC;&#x2122;s global product range and R+D resources for future product \ !

opportunities for MCG to take its product offering beyond South Africaâ&#x20AC;&#x2122;s borders into the rest of Africa will also provide growth.

18

FEBRUARY / MARCH 2014

â&#x20AC;&#x2DC;Acquisition opportunitiesâ&#x20AC;&#x2122; Â&#x201D;Â&#x201A; \=] ?

Â&#x203A;

prospects. We are excited to be supporting the robust management team of the business to achieve such growth prospects. Furthermore, we are actively exploring additional acquisition opportunities in the * Â&#x161; { * ?

MCG has a predominantly blue-chip customer base in a number of different industries; its products include crates and containers, pallets and chairs (for schools, auditoriums, passenger trains and stadia).

New MD for MCG opportunities Ian Victor has been appointed managing director of \=]* \ * Â&#x2020; Q engineer with an MBA, Ian has extensive experience in

^

Â&#x2122; then joined the Group 5 company Everite Building Products. In 2001 he joined Dunlop Industrial products in Benoni as works manager and, when Dunlop sold off its Industrial products division, moved to Pandrol SA as MD. Pandrol is a manufacturer of products for the mines and railways; he was MD of Pandrol Mozambique for the

_ ; Y

company, Sturrock & Robson Industries. â&#x20AC;&#x153;I needed a new challenge and this came about when I was offered the opportunity to join a consortium, which eventually bought

INDUSTRY NEWS

Tony Dean, who is wellknown in plastic pipe industry, has been appointed MD of the RARE Plastics

into pipe manufacturing.

The new division will trade under the name RARE Plastics. Dean previously managed some well-known plastic pipe businesses in South Africa and Botswana and comes with over 30 yearsâ&#x20AC;&#x2122; industry experience.

According to the CEO of RARE Holdings, Wally van Coller, this acquisition will improve RAREâ&#x20AC;&#x2122;s competitiveness in offering piping solutions to the industry by supplying a turnkey service ranging from

Wally van Coller of RARE group was formerly involved in pipe production at DPI

manufacturing through installation and maintenance.

RAREâ&#x20AC;&#x2122;s main activities will remain in Kliprivier while RARE Plastics will manufacture the HDPE pipe in Meyerton.

RARE has evolved through a management buyout and acquisitions from a specialist pipe supplier in 1975 through to the listed entity, RARE Holdings, in 2007 and ultimately to the current B-BBEE-accredited and transformed RARE Group.

Ian Victor has been appointed managing director of MCG, based in Malvern, Johannesburg

MCG Industries,â&#x20AC;? said Ian. â&#x20AC;&#x153;We plan to develop the group and grow !

â&#x20AC;&#x153;We understand it is a very competitive as many viable countries as possible. I industry but there are always opportunities believe the key to success is people, and available, even if it means some this will determine our growth path and the consolidation. It is a known fact that rate at which we grow, so we will look for

talented people to join MCG,â&#x20AC;? he added. fragments up to a point and then some consolidation takes place: maybe this holds true for our industry? www.zico.co.za )

) )~

FEBRUARY / MARCH 2014

19

INDUSTRY NEWS Prototyped components such as even fairly large housings are produced to scale on the Objet printer; here the process is overseen by Christo Botha, one of the engineers at Skeg

Skeg achieves design direction

BEAUTIFUL design is all well and good, but what actually matters is that a product sells and makes you money.

Thatâ&#x20AC;&#x2122;s the rationale behind the strategy at SKEG Product Development, a Cape Town design business which has put together a strong team for just this purpose and backed that up with a range of equipment to manufacture close-toidentical prototypes as well as moulds for short-run or trial production.

Skeg founder Pierre Becker, who trained as a mechanical engineer while in the Navy before becoming involved in plastic converting, was part of the team that oversaw the relocation of local production of the Freeplay â&#x20AC;&#x2DC;wind-upâ&#x20AC;&#x2122; radio to China in the 1990s. Although it appeared at the time that it would be far more cost-effective to produce the radios in the East, the process ultimately proved to be massively disappointing as the SA team lost control of the development process â&#x20AC;Ś but the experience led directly to the creation of Skeg. Becker believes the South African scenario is highly suited for active design and development and that there is a creative culture in the country to support this.

South Africa has a proud record of product development, with a lot of independent thinkers and mavericks active in the plastic moulding sector.

That was turned into reality during the sanctions era under the former regime in South Africa, when import substitution was a necessity. That period had barely drawn to a close in the mid-â&#x20AC;&#x2DC;90s,

To achieve fully functioning prototypes, all the necessary components are produced in-house at Skeg. The machinist deburrs and polishes tiny parts such as this accessory 20

however, when brand owners began to be enticed to manufacture in China. Chinese mould makers and convertors were offering very attractive rates, which led to the large-scale shift of mould manufacture as well as mould design and development to the East.

This was obviously disheartening for designers and mould makers around the country, but Becker resolved to start a prototyping business and Skeg was duly formed in 2004. The intention was to produce prototypes that would resemble

*

Skeg team has built on this standard since and produced work for over 150 customers.

It develops the technology for new products; does the industrial and electronic design; builds fully functional prototypes and handles functional lifetime testing. It designs for manufacture in either South Africa or the Far East. Â&#x201D; Y

attractive designs, but whatâ&#x20AC;&#x2122;s more important is to generate products that will be popular with consumers and sell â&#x20AC;&#x201C; otherwise you donâ&#x20AC;&#x2122;t actually have a product,â&#x20AC;? said Becker.

Skeg has focused on integrating the varied skills of its 20-strong team â&#x20AC;&#x201C; including industrial and electronics

FEBRUARY / MARCH 2014

JUST BRIEFLY

Best Plastics exits production in Cape Town, sells plant

Moulds for large components such as gym equipment are cut from polyurethane block. The

texturing is handled in a subsequent process.

Such large components are normally produced in composite materials, possibly by vacuum infusion

The main processes the company employs include: 3D printing; CNC turning and milling (for the cutting of metal or cast polyurethane slab); vacuum casting; overmoulding for short-run production; and low-pressure casting and fabrication. designers, mecatronics specialists as well as model makers and machinists â&#x20AC;&#x201C; to enable it to achieve good turnaround times and world class standards.

Using its in-house facilities, Skeg can manufacture products in the 5-500 unit range quickly and cost effectively, without the major outlay of expensive tooling. www.skeg.com

Skeg operates its own paint booth, allowing it to generate exactly the appearance required

FEBRUARY / MARCH 2014

21

BEST Plastics has ceased production in Cape Town and will in future operate as a distribution business in the Western Cape, supplying products from its parent company, Best Engineering of Turffontein, Johannesburg.

In what was virtually the end of an era for the area in which it operated, Phillipi, Best Plastics auctioned off the manufacturing equipment at its premises in Protea Road in January: the same large factory was used previously by the Harmed medical mouldings venture in the 1990s. That visionary business failed, after which Best Plastics took over the site and, under the management of Elsa Spiess, operated successfully for over a decade.

The company moulded mainly household items. But the operation became tenuous in recent years, leading Spiess and her father, Bruno Spiess of Best Plastics Engineer, to consider switching focus.

Last year they received an attractive offer for the property, which they accepted. Elsa now begins a new career as a distributor, supplying the Best range of products and potentially other products as well.

Hedge fund suggests Dow spin off petrochemicals AMERICAN hedge fund Third Point LLC purchased a stake in Dow Chemical in January and, incredibly, immediately urged the groupâ&#x20AC;&#x2122;s management to evaluate a spin-off of its petrochemical operations.

Third Point CEO Daniel Loeb called on Dow to hire advisors to conduct an assessment of whether its current ! Â

and aligns with Dowâ&#x20AC;&#x2122;s goal of transforming into a specialty chemicals company. â&#x20AC;&#x153;The review should explicitly explore whether separating Dowâ&#x20AC;&#x2122;s petrochemical businesses via a spin-off would drive greater stakeholder value,â&#x20AC;? Loeb said in a letter to investors. Dow shares were up 6% on news of this on 21 January.

Third Point did not disclose the actual size of its stake, but says Dow is now its largest current investment. Sources put the size of the investment at $1.3-billion, a roughly 2.3% stake based on Dowâ&#x20AC;&#x2122;s current market capitalization. Third Point has about $14 billion in assets under management. â&#x20AC;&#x153;The companyâ&#x20AC;&#x2122;s weak performance is even more surprising given that the North American shale gas revolution has been a powerful tailwind for Dowâ&#x20AC;&#x2122;s largest business exposure in petrochemicals,â&#x20AC;? said Loeb.

Packaging industry plays important role in recycling plastics

Johannesburg-based packaging solutions provider Damax Sebenza Pack operates from a 3 500 m2 manufacturing facility

Buying recycled products ensures sustainability RECENT studies have revealed that South Africa boasts the second highest plastics recycling rate in the world, with 18% of all virgin plastics produced in the country being processed for reuse.

However, according to Damax Sebenza Pack managing director, Brian Lovell, while the ranking is impressive, there is room for improvement, particularly within the local packaging industry.

Lovell says that although the annual percentage of plastic recycled in South Africa is slowly increasing, the total amount of plastic that is not recycled is rising due to annual increases in the amount of the material being produced.

Johannesburg-based packaging solutions provider Damax Sebenza Pack operates from a 3 500 m2 manufacturing facility that specialises in the production of plastic packaging for numerous products, including; food, cosmetics, gardening and industrial applications. The company processes 75 tons per month of a variety of plastics, including PET, PVC, PP and high impact polystyrene (HIPS) â&#x20AC;&#x201C; to satisfy

requirements.

Lovell says that PVC is particularly well recycled in the local industry, while PET is generally not.

He does, however, highlight the fact

driving a major initiative to use up to 30% recycled rPET in its food and beverage packaging by 2014 â&#x20AC;&#x201C; a move Damax Sebenza Pack fully supports.

Another major environmental advantage of PET and PVC is the fact that the raw materials do not go to waste during production. Brian adds: â&#x20AC;&#x153;One of the greatest advantages of these materials is that almost nothing goes to waste during the manufacturing process. The byproduct from both materials is used in the manufacture of numerous items, ranging

â&#x20AC;&#x153;In the USA, a polylactic acid polymer (PLA) bioplastic â&#x20AC;&#x201C; manufactured from carbon found in simple plant sugars â&#x20AC;&#x201C; has proven to be highly popular, as it is easy

PLA is manufactured by NatureWorks, a US-based company jointly-owned by Cargill and PTT Global Chemical. Brian points out that the implementation of PLA in packaging locally is challenging, as it is almost double the price of other materials, with no local recycling facilities.

Lovell points out that organisations can help to improve plastic recycling rates in South Africa by separating waste at source and by purchasing recycled plastic products. â&#x20AC;&#x153;Even if there are no recycling companies nearby, waste can still be easily separated at source to ensure

Damax Sebenza Pack managing director, Brian Lovell 22

FEBRUARY / MARCH 2014

easy access for waste pickers, who are

collections, thereby increasing collected tonnages. This not only increases the earnings of the individual waste picker, but also the total amount of plastics

* According to Lovell, the purchase of recycled products ensures sustainability, in addition to stimulating the plastic Â&#x201D;;

wrapping, supermarket carrier bags and garbage bags amount to approximately one third of recycled plastic products in South Africa. By making the simple decision to consciously purchase everyday products that are manufactured from recycled plastic, individuals and companies can continue to play their role in ensuring that South Africa remains a world leader in *

www.damax-group.co.za/sebenza2.htm

INDUSTRY NEWS

Coke testing shrink sleeve designed for easier recycling

BY JIM JOHNSON, PLASTICSNEWS

FULL-WRAP shrink sleeve labels are a marketerâ&#x20AC;&#x2122;s dream and a recyclerâ&#x20AC;&#x2122;s nightmare. But one of the largest companies in the world believes it is on to a solution for a problem thatâ&#x20AC;&#x2122;s been creeping up on the PET recycling industry in recent years.

Full-sleeve labels can fool optical sorting equipment into believing they are seeing coloured resin. They also can mix with and contaminate clear PET grind at the bottom of separation tanks. And they can become mixed in with PET from

lightweight water bottles because of their similar characteristics when recyclers use an elutriation process that uses air for sortation.

Bottles with full-sleeve labels account for about 5% of the recycled plastic bale these days and is expected to continue to grow in the years ahead.

Now Coke has developed a new label

!

;{Â&#x201A; ! & & Â&#x201A; &

from PET that settles to the bottom. =

Association of Postconsumer Plastic Recyclers compatible label â&#x20AC;&#x201C; a trade group that has been working to address shrink sleeve label impacts on recycling. The group has established a set of shrink sleeve guidelines to help manufacturers make their products more recyclable.

Coca-Cola tested thousands of bottles in real-world conditions by !

labels and pushing product through the supply chain to make sure this

` _

|

"!? | Â&#x201C; _ Â&#x201C;

_ ) ?

Â&#x201C;

_

"!?

new material would stand the test of time in real-world conditions. Cole also sent the bottles to a few different PET recycling plants.

With encouraging results, Coca-Cola decided to use the new shrink sleeve on its single-serve orb-shaped bottle available during the holiday season at Wal-Mart. Every one of those bottles has the new label. â&#x20AC;Ś and the last word from our very own AnnabĂŠ Pretorius (SAPRO) The South African Plastics Recycling Organisationâ&#x20AC;&#x2122;s (SAPRO) AnnabĂŠ Pretorius was extremely happy to hear the news! Â&#x201D;Â&#x201A; Â&#x201D;Â&#x201A;

shrink sleeve is certainly a step in the right direction. What is excellent news for me is that a brand owner is thinking about the end-of-life of his product at the design stage; actually thinking about the way the product will be recycled. This is exactly what SAPRO is asking from brand owners.

With all the check-boxes for market appeal, aesthetics, shelf life, etc, there should also be a check-box for recycling at its end-of-life stage. Congratulations, Coca =

www.plasticsrecycling.org FEBRUARY / MARCH 2014

23

Dickieâ&#x20AC;&#x2122;s 40yr career spanned the â&#x20AC;&#x2DC;bag revolutionâ&#x20AC;&#x2122; Played important role in open communication process at Nampak CHRIS Dickie of Nampak Flexible has retired from active duty after a 40-year career which virtually spanned the entire history of the plastic shopping bag to date.

Dickie was working as an industrial engineer trainee at Cullinan Refractories in Â&#x201C; ZÂ&#x201E;Â&#x2019;Â&#x2014;

about the â&#x20AC;&#x2DC;newâ&#x20AC;&#x2122; plastic bag, which was

$ _

potential customer, wanting to develop an all-weather plastic cement bag with Reed Corporation.

Dickie was approached by the young and dynamic Polyfoil Packaging management team to join them and, under the mentorship of Austrian-born technical manager Paul Meusberger, he started his career in plastic packaging. Polyfoil was at the time

=

ZÂ&#x201E;"Â&#x2C6; the reputed inventor of the â&#x20AC;&#x2DC;Paperliteâ&#x20AC;&#x2122; plastic shopping bag, Tommy Hutt).

Polyfoil had established a strong national structure by setting up four regional * ; Â&#x152; *

$* ; * Â&#x161; { ;{$

? = Â&#x201A; $ It was an exciting time: retailer demand for the Paperlite bags took off and the technology developed at a rapid pace. The

= ~Â&#x2021; microns thick, a yellow masterbatch colour

!

* = & !

and the famous â&#x20AC;&#x2DC;eâ&#x20AC;&#x2122;tchekkersâ&#x20AC;&#x2122; was born.

The next 30 years until 2003 saw constant improvement in extrusion and conversion technology as well as raw material advancement: the bag thickness

* ~Â&#x2021; ZÂ&#x201E;Â&#x2019;Â&#x2014; Z~ #Â&#x2021;Â&#x2021;Â&#x2014;* same carrying capabilities.

Career with Nampak Dickie had in the meantime switched to Nampak: ironically, his former employer,

= * ZÂ&#x201E;Â&#x2019;"

majority control of Nampak group and the business was renamed Reed Nampak Ltd. Â&#x161; ! * ZÂ&#x201E;Â&#x2019;~* Â&#x2022;

to the Nampak Polyfoil plant in Sander Road, Pinetown, where he was appointed factory manager. The bag evolution process continued at pace and a custom designed factory was constructed in Westmead, Pinetown.

Nampak Polyfoil in 1978 acquired ; Â&#x161;

* Johannesburg, and Dickie was transferred from Pinetown to manage the new amalgamated factory. The production equipment from the Pretoria factory was moved to the Johannesburg plant, which at the time was reputed to be the largest plastic packaging factory in the Southern Hemisphere.

In 1983, he was transferred to the Nampak Polyfoil plant in Bellville, Cape Town, and shifted from production to sales, taking up positions of general manager and sales director. The momentum did not drop; he could virtually enter a retail area and sell bags to just about every shopkeeper in sight! One of Polyfoilâ&#x20AC;&#x2122;s successes at the time was exporting container loads of printed carrier bags to supermarkets in the United Kingdom, Asda and Tesco being the most notable.

That phase came to an abrupt halt with the passing of the plastic bag legislation Z~ micron to 30 micron) and the introduction of the government bag levy in 2003. #Â&#x2021;Â&#x2021;" Â&#x161;

to exit the retail checkout bag market and the Nampak Polyfoil plant in Bellville â&#x20AC;&#x201C; which

Chris Dickie with some of the printed

manufactured at Nampak Flexible. Chrisâ&#x20AC;&#x2122; involvement in the packaging industry began with the development of HDPE shopping bags in 1973 and he continued with that until 2006; more recently heâ&#x20AC;&#x2122;s worked with reclosable

had been one of the top bag manufacturing factories in Southern Africa â&#x20AC;&#x201C; began a gradual decline that culminated with its Â&#x201A; #Â&#x2021;Â&#x2021;" That year Dickie relocated to the Nampak Flexible Packaging plant in Ndabeni, Cape Town, where the group was involved in the

and pouches for the multi-national FMCG companies.

Dickie has enjoyed the Nampak culture throughout his four decades of service, and played a key role in the process. He coined the â&#x20AC;&#x2DC;moreâ&#x20AC;&#x2122; concept, which implied that one of the best strategies for a company to gain customer loyalty was for all its employees to deliver â&#x20AC;&#x153;more value for the same priceâ&#x20AC;?. This theme has played an important role in the retention of the groupâ&#x20AC;&#x2122;s valued customers â&#x20AC;&#x201C; well done Chris!

Next phase(s) Chrisâ&#x20AC;&#x2122; strategy from here involves two new ^ Â&#x201D;; # * * cycling, golf and tennis will take priority.

And phase 3 is possibly a training function.â&#x20AC;?

Brief history of Nampak CHRIS Dickieâ&#x20AC;&#x2122;s four decades in the plastic industry overlapped almost entirely with the formation and history of the Nampak group to date, and makes for interesting. The sequence, based on the book â&#x20AC;&#x2DC;The Making of Nampakâ&#x20AC;&#x2122; by Anthony Hocking, was as follows.

1964 Tommy Hutt forms Polyfoil Packaging in Pretoria; 1968 National Packaging/Natpack and Amalgamated Packaging Industries/API agree to merge through 24

FEBRUARY / MARCH 2014

a new holding company, National Amalgamated Packaging Ltd â&#x20AC;&#x201C; or NAMPAK; 1970 Reed group takes over Polyfoil Packaging of Pretoria, notable for its â&#x20AC;&#x2DC;Paperliteâ&#x20AC;&#x2122; shopping bags made from HDPE; 1976 Reed achieves majority control of (June) Nampak by buying the 31 percent of Nampak shares held by St Regis, and also buys Oscar Frumanâ&#x20AC;&#x2122;s stake; 1976 Nampak reregistered as â&#x20AC;&#x2DC;Reed

(Sept) Nampak Ltdâ&#x20AC;&#x2122;; 1977 Reed Nampak takes over Reed Corporationsâ&#x20AC;&#x2122; packaging interests, one of which was Polyfoil; 1978 Reed Nampak taken over by Barlows (July) Packaging and renamed Nampak Limited; 1978 Nampak Limited acquires Rubenstein (Nov) Plastics, which operated a factory in

Â&#x161;

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Polyfoil Pretoria transfers to

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PEOPLE

Interpack just around the corner!

INTERPACK will take place at the DĂźsseldorf exhibition grounds from 8-14 May, and is again building on the Innovationparc packaging and Metal Packaging Plaza, the special themes that were so successful at interpack 2011. â&#x20AC;&#x153;The elaborately planned and organised special themes have now become a hallmark of Interpack and attracted much acclaim. We shall therefore continue to do all we can to carefully prepare forward-looking topics with our partners from industry and present them visually and thematically to the highest standards,â&#x20AC;? said Bernd Jablonowski, Interpack Director. Pictured here at a breakfast seminar in November in Johannesburg to promote the fair were, Werner Dornscheidt, president & CEO of Messe DĂźsseldorf, F. Klefenz, director of Interpak and president of Robert Bosch, and Carryn Todd and Marc Cousins, both of the Southern African-German Chamber of Commerce and Industry. www.interpack.com

SA thermoforming fundi transfers skills in USA IAN Strachan at the Gordonâ&#x20AC;&#x2122;s Bay waterfront, during a recent visit to the country. He has found

_

thermoformed polystyrene trays, to be of a very high level in South Africa. In the USA, says Ian, brands owners wanting high quality have to pay a premium

THERMOFORMING fundi Ian Strachan has transferred many of the skills gained in South Africa for effective use in the USA, where he has been involved in thermoforming consulting and training for the past two decades.

Originally a millwright and engineering trainee with Iscor in the ZÂ&#x201E;"Â&#x2021; * ?

ZÂ&#x201E;Â&#x2019;Â&#x2021; he was general manager of the blow moulding business Elvinco Q \ Q $* Â&#x2018; ZÂ&#x201E;Â&#x2019;Â&#x2C6; ZÂ&#x201E;Â?Â? Â&#x2018; he was MD of the thermoforming business Mono Containers.

He then joined Sun Packaging in Atlantis, a company which challenged the conventional leaders in the polystyrene foam thermoforming sector with some unconventional strategies and products. After 1992 Ian became involved in consulting to the

$ Â&#x192; \]Q Inc of the United States. Heâ&#x20AC;&#x2122;s been consulting in this area for the past two decades. â&#x20AC;&#x153;I am working wherever I can help in the USA and occasionally other strange places,â&#x20AC;? says Ian. â&#x20AC;&#x153;My son, Mark, has made his mark in the US in the thermoforming industry and is now chairman of the SPE thermoforming division.â&#x20AC;?

Ian and his son run several training programmes in the USA in between their respective consulting projects. The SPE thermoforming conference in Atlanta in September is an annual event where Mark and Ian host a one-day thermoforming workshop. â&#x20AC;&#x153;I also occasionally get involved in waste management and PET bottle projects in various parts of the world, but still mainly with roll fed thermoforming companies,â&#x20AC;? Ian adds.

Mark and Ian also serve on the Advisory Board of Penn State Universityâ&#x20AC;&#x2122;s College of Plastics Innovation and Technology.

Intrinsysâ&#x20AC;&#x2122; Giuliano back from 6 months in the UK GIULIANO Minucci has recently rejoined the Intrinsys engineering services team after six monthsâ&#x20AC;&#x2122; training at Intrinsys in the UK. Giuliano is now charged with delivering his newly developed experience and skill back in South Africa. During his secondment to the UK, Giuliano was exposed to all aspects of the company and was involved in a number of engineering projects, software support activities and training activities.

Giuliano has a bachelorâ&#x20AC;&#x2122;s degree in mechanical engineering from the University of the Witwatersrand. His lifelong interest in motor racing and the automotive industry is the primary reason for choosing a career in mechanical engineering and his four years at university fuelled his passion and excitement for high-performance engineering and innovative thinking. While at university, Giuliano developed strong design skills as he worked in a closeknit team on a high performance internal combustion engine and enjoyed his

Â&#x192; ?; { leading SA production car racing series team) performing a number of tests and analysis on the torsional rigidity of a roll cage.

Welcome back Giuliano!

Sun Ace board appointments SUN ACE South Africa has appointed two new directors, with Alistair Calder and Veronique-Chantelle Mew joining the groupâ&#x20AC;&#x2122;s board in January.

Alistair, who is well recognised for his prowess in PVC converting locally and regionally in African markets, has been appointed as an executive director, and will champion the companyâ&#x20AC;&#x2122;s vision to take advantage of economic growth north of our borders.

Alistair was invited to join the Sun Ace Group technical department to provide specialist skills developing business opportunities internationally. His competence was instrumental in supporting the groupâ&#x20AC;&#x2122;s investment in South America. He will also progress business opportunities on the subcontinent, where the group has been present for over 12 years. During 2013 Sun Ace Kenya was established; the business unit has a fully equipped technical service centre.

Veronique, who has a B Comm from Tukkies, completed

=Q ?Q$ ; = Y { Q Â&#x2022; #Â&#x2021;Â&#x2021;~ Â&#x201A;

; =Y { ? Â&#x192; ? Q

and effective 1 January this year joined the board as an executive director of Sun Ace South Africa. _

to Sun Ace South Africa, developing its overall African strategy alongside new investments in non-vinyl production.

Alistair Calder

VeroniqueChantelle Mew FEBRUARY / MARCH 2014

25

Foundation Lecture, 13 March, in Boksburg KEN BARNES, rubber business unit manager for Protea Polymers, will give a presentation titled â&#x20AC;&#x2DC;How Globalisation and the Economy has Impacted on the South African Rubber Industryâ&#x20AC;&#x2122; at the Institute of Materialsâ&#x20AC;&#x2122; Foundation Lecture at the Birchwood Hotel in Boksburg on Thursday 13 March.

The event â&#x20AC;&#x201C; the 32nd occasion on which the IOMÂł has hosted the Foundation Lecture â&#x20AC;&#x201C; is being presented by the Instituteâ&#x20AC;&#x2122;s Northern Branch.

Ken has been involved in the rubber industry for a whopping 38 *

market and more â&#x20AC;&#x2DC;recentlyâ&#x20AC;&#x2122; in the

material supply sector, with Protea group. Heâ&#x20AC;&#x2122;s also assisted the IOMÂł over many years and knows the industry well, so his presentation will be enlightening.

Accommodation is available at the Birchwood Hotel; for more info, contact one of the IOMÂł branches.

Ken Barnes of Protea Polymers

Ken gets in practice with IOM3 web upgraded rubber additives chat KEN BARNES, the man who is going to give the IOMÂł Foundation Lecture in March, got some practice in when

Â&#x20AC; Â&#x2014; &

of the year in November. His title was â&#x20AC;&#x2DC;Compounding with Antioxidants and Anti-ozonants,â&#x20AC;&#x2122; which included a brief history of antioxidants and anti-ozonants in rubber.

Ken highlighted the theory of oxidation and the effects of vulcanization and antioxidants. He discussed the rate of oxidation due to temperature, light and motion.

He also listed important properties of antioxidants and antiozonants and concluded his presentation with the various types of these additives used in the rubber industry. The function, held at the Victoria Country Club in Maritzburg, was sponsored by Protea Polymers, a member of Omnia group.

26

THE IOM3â&#x20AC;&#x2122;s website address has changed and has also undergone an upgrade and is now more user-friendly. Information covered on the website includes links to our Patron membersâ&#x20AC;&#x2122; websites, information on membership, the constitution, branch contact details, information on Education, Events and news about the association.

www.iom3.co.za

Institute of Materials: Southern Africa Region www.iom3.co.za www.iom3.org

Eastern Cape Coen Burger Â&#x2021;Â?# Â&#x2C6;~" ""~" coenburger@axxess.co.za

National Chairman AndrĂŠ Cornelius Â&#x2021;Â&#x2019;Z "Â?# Â&#x201E;Â?Â?~ andrec@orchemtrading.co.za

Northern Spike Taylor p. 011 928 4172 Â&#x2021;Â?# Â&#x2C6;~" ~Â&#x2019;Â&#x2014;Â&#x2C6; spiket@multotec.co.za

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

Secretary Wendy Knott-Craig Â&#x2021;Â&#x2019;Â&#x2014; #Â&#x2021;Z Â?"Â&#x201E;Â&#x201E; wknottcraig@vodamail.co.za

FEBRUARY / MARCH 2014

VIRGIN POLYMERS & RECYCLED MATERIAL

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young academic

Hong Kong, the inviting venue for the competition, has one of the most impressive night skylines anywhere

28 FEBRUARY / MARCH 2014

Tuks student wins IOMÂł global lecture event THE exposure and experience gained on a trip to the Far East for young individuals can be invaluable. That certainly was the case for Cornelis van Niekerk, the South African entrant in the IOMÂłâ&#x20AC;&#x2122;s Young Personsâ&#x20AC;&#x2122; World Lecture Competition in Hong Kong in October 2013.

Cornelis travelled to the Far East with the IOMÂł secretariate Wendy Knott-Craig for a 6-day tour which involved visits to industrial and research locations as well as cultural experiences in the company of fellow entrants from Brazil, Hong Kong, Ireland, Malaysia, Singapore, the United Kingdom and USA â&#x20AC;&#x201C; all countries where the IOMÂł is strong.

The tour included visits to a large recycling plant; the Hong Kong Polytechnic University; a construction site on the MTR underground/subway transportation system, which is being extended; the Haesl plant, where repairs and overhauls of Rolls-Royce aircraft engines are conducted; and visits to two power plants (where coal imported from Singapore is used).

Besides that, the group also received a

thorough â&#x20AC;&#x2DC;introductionâ&#x20AC;&#x2122; to Chinese cuisine and enjoyed a cruise on a junk â&#x20AC;&#x201C; courtesy of the IOMÂł HK members â&#x20AC;&#x201C; to Lamma Island that included watching sunset over Hong Kong.

The lecture competition itself, held at the Hong Kong Jockey Club, was both intense and entertaining, with high standard presentations from all the participants.

Cornelis was phenomenal on stage, with his passion for his topic, â&#x20AC;&#x2DC;Novel Technique for in-situ laser alloying of AISI 410L stainless steel with nitrogen during laser cladding,â&#x20AC;&#x2122; quite evident. Cornelis, who is studying towards a Masters degree in metallurgical engineering at the University of Pretoria, also performed well during judgesâ&#x20AC;&#x2122; question time.

Dr Phil Bischler, senior vice-president of the IOMÂłâ&#x20AC;&#x2122;s in London who has visited South Africa on a number of occasions, then announced the winners: third place went to Adam Brown of the UK and Hendrik Hans of Singapore was adjudged as the runner-up. The South African attendees were thrilled when Cornelis was announced as the winner: congratulations

The students visited power stations as well as an underground construction site on the MTR subway system, which is being extended: witnessing the challenges of this complex undertaking was

are due to the Tukkies student.

That evening the contingent was bussed to The Peak to enjoy a celebratory dinner at CafĂŠ Deco, one of the territoryâ&#x20AC;&#x2122;s most successful restaurants. The evening ended with a few cocktails at a nightclub at the top of the tallest building in Kowloon with, once again, phenomenal views of Hong Kong Island.

Wendy was also able to attend the IOMÂł International Affairs Forum meeting, which was held before the lecture competition,

from the experience of the other IOMÂł delegates. Â&#x201A;

academic is the opportunity to visit industries of a global nature, to participate in experiences they would not have in their own country, to network with other like-minded individuals and to enjoy a new culture.

Itâ&#x20AC;&#x2122;s the type of international experience that could be of huge value to all young people entering the industry, many thanks to the IOMÂł. www.iom3.org Cornelis and Wendy enjoyed the vibe at the night markets in Hong Kong, with shopping and eating being interspersed with karaoke, and quite a bit besides

www.petco.co.za

SAPPMA has welcomed the South African Bureau of Standardsâ&#x20AC;&#x2122; (SABS) announcement that all PVC pipes manufactured in South Africa have to be free of heavy metals

by July 2015. ? \ ?Q'?* ? Â&#x2022; *

earlier that the technical committee of the SABS has amended its standards to ensure that all heavy metal stabilisers are removed in the manufacturing of PVC pipes. â&#x20AC;&#x153;Local manufacturers of PVC pipes have been granted a window period of 18 months to get their house in order and to comply with the new legislation,â&#x20AC;? Dhlamini said, adding that the SABS will be the custodian of the new standard and enforce the new legislation. Pipes bearing the SABS mark of quality would have to be resubmitted for testing, after which new permits will be issued.

SAPPMA chairman Jan Venter said that the association welcomed the decision by the SABS. â&#x20AC;&#x153;SAPPMA already embarked on a voluntary removal of heavy metal stabilizers from PVC pipes back in 2006 because it added value to SAPPMAâ&#x20AC;&#x2122;s life cycle thinking and took into account endof-life issues and waste management options. The reason for the initiative was based on health and environmental considerations and was done at considerable cost to our members,â&#x20AC;? Venter explained.

The policy was fully implemented by SAPPMA in July 2009 and applied to drinking water systems as well as

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heavy metal free by 2015

sewer, drainage and mine pipes. As a result, all PVC pipe manufactured by SAPPMA members are lead-free and are stabilised with environmentally friendly materials such as calcium zinc or organics based stabilisers instead.

www.sappma.co.za

www.sabs.co.za

FEBRUARY / MARCH 2014 29

ASSOCIATION NEWS

SAPPMA signs cooperation agreement with SAICE

www.sappma.co.za 30 FEBRUARY / MARCH 2014

www.saice.org.za

SAPPMA has signed a Memorandum of Understanding (MoU) with the South African Institution of Civil Engineering (SAICE) aimed at expanding the associationâ&#x20AC;&#x2122;s reach to the new generation of engineers entering the South African market. â&#x20AC;&#x153;It is important for the local pipe industry to ensure an & !

the sector,â&#x20AC;? said SAPPMA CEO, Jan Venter.

The MoU encourages the two parties to cooperate to lobby and challenge statutory legislation and structures to facilitate the achievement of their common objectives.

Some of the areas of cooperation agreed on include the mobilisation of resources, where the two parties have agreed to support each other in sourcing funds for the implementation of their activities and plans that fall within the framework of the MoU. The agreement also entails a commitment to enhance and support each party in the creation and maintaining of relations with similar international institutions. With SAICEâ&#x20AC;&#x2122;s backing, SAPPMA will be able to participate in graduate engagement programmes at various universities in the country and spread the message about the need for engineers who are dedicated to advancing the pipes and plastic industry.

Rotation 2014 heads for Cape Focus on sustainability and design Â&#x201A;_ ? Y Q \?Q conference will be held in Cape Town on 29 and 30 May. The ARMSA team is busy organising the annual event, to be presented at the beautiful < _ The Rotation conferences have proved successful and grown in popularity over the years. Some big names in the rotation industry have shown interest in presenting papers and delegates across the globe

attendance.

The focus of this yearâ&#x20AC;&#x2122;s }Â&#x2022; Y }? Y Cape Town has recently

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one place to visit this yearâ&#x20AC;&#x2122; by the New York Times. The city has apparently secured the top spot ahead of Los Angeles, the Vatican and the Seychelles islands. Its natural beauty, diversity of its people and the role it played in the victory of democracy were attributed to making the city a preferred destination for people from around the world.

Anyone interested in attending, presenting a paper, exhibiting or sponsorship can contact Petro Geldenhuys at info@armsa.co.za.

Also, keep your eye on the ARMSA website for further information. www.armsa.co.za

SAPPMA 5th annual golf day SAPPMAâ&#x20AC;&#x2122;s 5th annual golf day will take place on Thursday, 20 March at the Copperleaf Golf Estate. Built on land once lived on by Ernie Elsâ&#x20AC;&#x2122; grandfather, Ernie Vermaak, = ? Q Y { Club, and the second signature Ernie Els designed golf course in South Africa. â&#x20AC;&#x153;We are very excited to host this yearâ&#x20AC;&#x2122;s Golf Day at a

} Y â&#x20AC;&#x201C; the layout tests every aspect of the game and provides even the longest hitters with a challenge. The course is one

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* and players experience a sense of openness and freedom with the Magaliesberg backdrop adding to the country atmosphere,â&#x20AC;? says SAPPMA CEO, Jan Venter.

Entry fees for four balls are R3 500 and SAPPMA is inviting all golfers to enter early to enjoy a great round of golf, fun and relaxation. The dayâ&#x20AC;&#x2122;s activities will once again conclude with a gala dinner at the clubhouse, during which various prizes will be awarded.

The following sponsorship opportunities are available: Tee: R4 000; wet hole: R4 000; green/hole: R3 000. Other sponsorships could include caps, shirts and team prizes.

For more information or entry forms, visit the SAPPMA website or contact Louise Muller via email on admin@sappma.co.za.

FEBRUARY / MARCH 2014 31

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by Francis Huysman (EPRO co-chairperson/ Val-l-Pac) and on the right, Geraud Delorme (EPRO co-chairperson/Valorplast) and EPRO Secretary General, Peter Sundt

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TEL: +27 (0) 11 462 2990

SOLUTION

MACHINERY (PTY) LTD â&#x20AC;&#x153;One total solution for Injection Mouldingâ&#x20AC;?

FAX: +27 (0) 11 462 8229 e-mail: jacques@demaplastech.co.za

www.petco.co.za

The PETCO team who helped to make the colloquium the success it was â&#x20AC;&#x201C; Sahra Heuwel, Agripa Munyai, Nabilah Hassen, Cheri Scholtz, Belinda Booker, Lisa Parkes, Monique Holthausen and Oscar Baruffa

Plastics|SA takes to the airwaves!

First-ever Plastics|SA advertising campaign on radio PLASTICS|SA will be telling the plastics story in a series of light-hearted, but educational English and Afrikaans radio spots that will be kicking off at the end of February 2014.

According to Monya Vermaak, Plastics|SA Marketing and

association is advertising on broadcast media, although the decision has been a long time coming.

Propak in Johannesburg last year, the industry made it clear that they wanted to see more pro-active marketing of plastics as a material to a wider audience. This has given us the mandate to proceed with our plans and long-term strategy to hit the airwaves with the message about the good qualities of plasticsâ&#x20AC;?, Vermaak said.

Three national radio stations have been selected based on the demographics of their listenership and ability to reach a wide selection of the industryâ&#x20AC;&#x2122;s target market. â&#x20AC;&#x153;We have selected SAFM, Radiosondergrense (RSG) and 5 FM for the

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February and at various time slots,â&#x20AC;? Vermaak said. "

#

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ADVENTURER Ray Chaplin celebrates the end of his 2,460km river boarding journey down the length of the Orange River.

Sponsored by Plastics|SA and Nampak Rigid Plastics, Ray started his quest in April 2013 from the riverâ&#x20AC;&#x2122;s source in Lesotho, reaching Alexander Bay in early December.

Doing presentations on environmental responsibility and the importance of living sustainably to schools along the way was part of the programme. Ray presented to over 9,500 learners along the river with over 5,500 bags of litter collected by schools and communities.

February, March and April and will raise awareness of the versatility of plastics, and that this is a material that has made modern convenience a possibility.

A second three month campaign will begin during the Monya Vermaak, Plastics|SA Marketing and last week of May, focusing more Communications Executive on the message of plastics recycling. â&#x20AC;&#x153;We are hoping to conclude this yearâ&#x20AC;&#x2122;s advertising campaign with a broader selection of radio stations and possibility also a television advertising campaign on selected DStv channels, which will coincide with our national Clean-Up and Recycle campaign which take place in September each year,â&#x20AC;? Vermaak explained.

Last year alone, Plastics|SAâ&#x20AC;&#x2122;s website and social media platforms attracted close to 8 000 unique visitors per month, while its public relations strategy generated exposure worth more than R18 million â&#x20AC;&#x201C; compared www.plasticsinfo.co.za to R4.5 million during 2012.

Epic Orange River journey ends

www.RayChaplin.com

New faces at PSPC Thinus Prinsloo has been appointed as Recycling Co-ordinator for the Polystyrene Packaging Council (PSPC). Prior to joining the PSPC, Thinus was involved in various government departments over the past 21 years, including the Department of Health, Department of Rural Development and Land Reform and the Department of Environmental Affairs. His main area of focus will be coordinating the collection of polystyrene from collectors for recycling around the country, and facilitating the entire process making use of the new PolyNet software. He will also be responsible for conducting training on polystyrene recycling and help to educate the general public and schools about the process 34

FEBRUARY / MARCH 2014

Wesi Jillian Mathebe has

Administrator for the PSPC. Wesi has ample experience

reception, having worked in a busy medical practice at Life Fourways Hospital. Wesi will also assist the PSPC directors with the administration and communication process

Investment in research and design resulted in phenomenal growth DESPITE a challenging economic climate, cheap imports threatening our local manufacturing industry, expensive operating costs and other obstacles, the South African plastics industry has managed to achieve impressive growth in all areas this past year. â&#x20AC;&#x153;Few industries in South Africa, and indeed around the world, have seen such rapid growth, technological advancement, innovation and a changing business environment, as we have in the local plastics industry this

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Philip de Weerdt, said. â&#x20AC;&#x153;We were forced to embrace change, adapt and face enormous challenges in a struggling economy that doesnâ&#x20AC;&#x2122;t always facilitate local manufacturing. However, we managed to make headway on many important challenges facing the plastics industry this past yearâ&#x20AC;?.

Continued growth over past 5 years De Weerdt said the industry has seen a consistent year-on-year growth since 2008. â&#x20AC;&#x153;Last year the South African plastics industry grew by 5.4%, despite the fact that the GDP only achieved a 0.9% growth for the same year. Plastics manufacturing contributed approximately 1.6% to South Africaâ&#x20AC;&#x2122;s GDP and 14.2% to the manufacturing sector during 2013.

The combined turnover of the industry is currently in the region of R50 billion per annum and consumption is approximately

Executive Director of Plastics|SA, Anton Hanekom with guest speaker Andre du Toit

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said.

De Weerdt said this marginal year-onyear improvement is expected to continue in 2014 as a result of investments made by plastic manufacturers and recyclers.

Developing new export markets Europe continued to be the largest export market for plastic products during 2013, although a growing demand for plastic packaging has also been noticed from other African countries. â&#x20AC;&#x153;Africa has seen major investments and expansions in its infrastructure, energy, telecommunications and manufacturing activities. These growth areas have had a direct impact on the economies, resulting in the demand for plastic packaging in Africa growing by approximately 8% this past year. This is higher than the current demand for plastic packaging in Western Europe and we are preparing to see growing competition from other African countries competing to meet this demand as international companies are becoming aware of this lucrative, new market,â&#x20AC;? De Weerdt said.

Plastics and sustainability Plastics|SA continued to make good progress on improving recycling rates through its Sustainability Council. Various initiatives took place throughout the year, such as beach and river clean ups, recycling awareness campaigns and sustainability initiatives, to help raise the publicâ&#x20AC;&#x2122;s awareness about the importance

of ensuring that their plastics are recycled and that they view plastic as a valuable resource that needs to be recycled

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De Weerdt added that the demand for recycled plastic as a way of combating the growing costs of importing virgin raw material is expecting to impact the local plastics industry in the years to come. â&#x20AC;&#x153;The growing number of environmentally conscious consumers will continue to put pressure on brand owners and retailers to include recycled material in their products. = > ? #

the plastics industry as a potential growth

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manufacturing industry,â&#x20AC;? he explained.

Facing future challenges head on De Weerdt said a decrease in the demand for plastic in the coming year is not expected. â&#x20AC;&#x153;However, we are expecting that local manufacturing costs will continue to be negatively impacted by escalating electricity costs, increased labour costs versus reduced worker productivity, higher transportation costs and the continued threats of cheaper imports and dumping of inferior plastic products,â&#x20AC;? he added.

Other challenges include technological # @ $

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because it requires high capital input), increased delivery costs (due to the nature of plastics manufacturing, industries are not in close proximity to their markets) and skills shortage. www.plasticsinfo.co.za

Graeme Smith of Vinmar International Ltd, Fernando Monteiro, MD of Tega Industries South Africa and Les Whittal of Advanced Polymers

Loutjie de Jongh, MD of Mpact Limited, was elected to the board

FEBRUARY / MARCH 2014 35

ASSOCIATION NEWS

Major growth gives SA plastics industry a bullish outlook

Plastic micro debris most prevalent litter on beaches 7 532 volunteers in Cape, 6 000 in KZN for International Coastal Clean-Up PLASTICS|SA, the coordinator of South African volunteers participating in the annual International Coastal Clean-Up (ICC), has just released the results for the Cape Provinces of the 28th International Coastal Clean Up which took place in September.

According to John Kieser, sustainability manager of Plastics|SA and national coordinator for the ICC, this is the worldâ&#x20AC;&#x2122;s biggest volunteer effort for ocean health. This year in the Cape alone (Northern, Western and Eastern Cape, and Marion B #Q !

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Various diving clubs took the initiative to coordinate underwater clean-ups in harbours, whilst a beach clean-up also took place on Robben Island. KwaZulu-Natalâ&#x20AC;&#x2122;s beach clean-ups attracted more than 6 000 volunteers with 1 600 youths attending a beach clean-up in the Durban Mangroves.

A total of 90 732 items were collected from beaches in the Cape

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new data sheets helped to highlight the growing concern over plastic and glass micro debris on our countryâ&#x20AC;&#x2122;s beaches.

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Top 10 items collected from beaches in 2013 Cigarette Butts

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Take Out/Away Containers (Foam)

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Glass Pieces

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Food Wrappers (candy, chips, etc)

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Polystyrene Micro Debris

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ASSOCIATION NEWS

This year in the Cape alone, 7 532 volunteers picked up litter and

_ data sheets which were developed by Ocean Conservancy. KwaZuluNatalâ&#x20AC;&#x2122;s beach clean-ups attracted more than 6 000 volunteers with 1 600 youths attending a beach clean-up in the Durban Mangroves Land Cleanups Number of people

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Weight of debris collected

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Plastic micro debris was by far the most prevalent litter source on the beaches, followed by bottle caps, beverage bottles, food wrappers and straws. â&#x20AC;&#x153;With the focus changing to material smaller than 2, 5 cm

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as the macro item mostly collected.

An interesting outcome of the clean-ups which took place in the Overberg was the presence of a large number of unused condoms. The coordinators have suggested that this is due to the large scale of poaching activities of abalone and rock lobster where the condoms are used to cover their main source of communications â&#x20AC;&#x201C; cellular phones.

Thank you to the sponsors Plastics|SA would not have been able to coordinate the annual International Coastal Clean-Up and achieve this success without the support of partner organisations. Sponsors of this yearâ&#x20AC;&#x2122;s event included: Pick â&#x20AC;&#x2DC;n Pay, Tuffy Manufacturing, Kelpak, Plastic|SA (Sustainability Council Members: PETCO, POLYCO, SAVA, PSPC, SAPRO), National Recycling Forum, Rose Foundation, Glass Recycling Company (GRC), Collect-a-Can (CAC), Coca Cola â&#x20AC;&#x201C; Fortune Bottlers, USABCO, Woolworths, Department of Environmental Affairs: Branch Oceans and Coasts, KZN Wildlife. www.cleanup-SA.co.za

www.plasticsinfo.co.za FEBRUARY / MARCH 2014 37

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ASSOCIATION NEWS

SAVA welcomes three new members in one month THE Southern African Vinyls Association (SAVA) has welcomed three new companies as members to the association â&#x20AC;&#x201C; CJP Chemicals, Eastman Chemicals and Betafence South Africa.

CJP Chemicals is a leading importer, stockist and distributor of chemical raw materials and ingredients into the South African market. (www.cjpchemicals.co.za) Eastman Chemicals is a global specialty chemical company that produces a broad range of advanced materials, additives and

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in products people use every day. â&#x20AC;&#x201C; www.eastman.com Betafence South Africa is an industry leader in manufacturing innovative architectural and security fencing (coated in PVC) and gate systems. (www.betafence.co.za) According to SAVA CEO, Delanie Bezuidenhout, these new members all decided to join SAVA after hearing about the work the association is doing through its Product Stewardship Programme (PSP).

SAVA currently represents close to 80% of the local PVC industry with 34 members. As the representative body of the Southern African vinyls industry, SAVA is ideally positioned within the local plastics industry with representation on the Recovery Action Group (RAG), the Packaging Council of South Africa (PACSA) and the Plastics|SA Sustainability Council to ensure that its members are represented on a broader platform.

SAVA also participates in knowledge transfer activities with the Australian Vinyls Council, The Global Vinyls Council, Vinyls Plus and other international organisations. Its main purpose is representing its membersâ&#x20AC;&#x2122; interests in the Southern Africa region

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and sustain markets for the polyvinyl chloride (PVC) business.

38

SAVA members who have committed to the Associationâ&#x20AC;&#x2122;s Product Stewardship Programme â&#x20AC;&#x201C; front from left, Maria Stephanou (SASOL), Pat Govender (NCP Chlorchem), Andy Halls (Floorworx), Charl Fourie (Capital Polymer Additives), Mark Holtes (Isegen), Nico Scheepers (independent consultant). Back from left,

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Dates to diarise The SAVA AGM on 9 April SAVA will also be representing the local vinyls industry at the PVC2014 conference in Brighton Vinyl Sustainability Conference hosted by SAVA in October which will be attended by members of the Global Vinyls Council Enquiries about membership should be directed to Delanie Bezuidenhout via email at Delanie@savinyls.co.za or telephonically at (082) 444-6866. www.savinyls.co.za

FEBRUARY / MARCH 2014

Welltec Plastics has the injection moulding machines to meet your requirements.

Excellent prices on existing stock PO PO Box Box 4567, 4567, Luipaardsvlei Luipaardsvlei 1743 1743 Tel: Tel: (011) (011) 762 762 5231 5231 -- Fax: Fax: (011) (011) 762 762 5228 5228 Mobil: Mobil: 083 083 255 255 9865 9865 Les Les Porter Porter Email: Email: spark@mweb.co.za spark@mweb.co.za Website: Website: www.edmshop.co.za www.edmshop.co.za

Xyris Technology plays active role in plastics additive R&D SOUTH African custom plastics additive compounder, Xyris Technology, understands the importance of research and development in the ever-changing chemicals industry and plays an active role in supporting research activities in South Africa.

The Bashewa-based company has worked with the Institute of Applied Materials (IAM) at the University of Pretoria to supply the masterbatches that were used in the manufacture of an insecticidal wall lining developed by the University to counter the spread of malaria.

This novel product combines the advantages of mosquito bed nets with the indoor residual spraying of walls.

Field trials started two years ago and the product is performing very well. Xyris " $

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product will eventually make it possible to phase out DDT, the controversial chemical currently used to ward off mosquitoes.

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masterbatches and compounds. These include products for deep underground mining applications that comply with the Â&#x2030;

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Proprietary UV stable masterbatches

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stadium chairs manufactured locally for football stadia used during the 2010 Soccer World Cup hosted by South Africa.

While many of these products are bromine-based, an exciting New development â&#x20AC;&#x201C; the use of nanostructured materials

new development is the use of

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are exposed to high heat they expand in a worm-like retardant systems. This includes manner as seen here in the electron microscope image, special intercalated graphite-based increasing in volume more than one hundred times additives. When such graphite

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license to the CSIR, which are also they expand in a worm-like manner exported worldwide. The corrosion inhibitor increasing in volume more than one range includes proprietary products as well hundred times. as formulations licensed from the CSIR When products containing this additive and supplied under contract to a major

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char layer is formed that prevents further

degradation of the polymer substrate. used to package steel products that are Current expandable graphite grades exported via ocean shipping.

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retardants in polyethylene, PVC and also www.xyris.co.za/frames.html in polyurethane foams. Xyris Technology

FEBRUARY / MARCH 2014 39 future growth in this type of halogenfree system.

Xyris Technology also produces the well-known purging compounds, Extru-Clean and Functional Additives for property Eco Purge under

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Flame Retardants Insecticides & Biocides Pro-degradants Volatile corrosion inhibitors

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OFFICE:

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www.xyris.co.za

New Venus plant â&#x20AC;&#x201C; The new plant for the construction & ' **

+ 0 Ningbo, has a production area of 120,000m² and capacity for up to 10,000 machines a year

Haitian expands fully-electric line Venus continues to gain ground: now available up to 5500kN HAITIAN International, which has since 2010 been a world market leader in terms of injection moulding machines sold, continued its steady progress development with an outstanding display at the K show in DĂźsseldorf in October last year.

The company was founded in 1966 in Ningbo, China, by Zhang Jinzhang, and in the course of the past 40-plus years has grown to be a listed company with a consolidated turnover in 2012 of about â&#x201A;Ź785-million (approximately R1.1-billion).

Currently, the Haitian group of companies serves around 30,000 customers in more than 130 countries. â&#x20AC;&#x153;The success of the

customer has always been pivotal for Haitian International. We became a global market leader as a result of our consistent customer orientation,â&#x20AC;? said Jinzhang. "

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The Venus II machine has a new injection unit and a more compact shape; fewer individual components provide for greater stability and dynamics in the injection process. The optional packaging version of the Venus II â&#x20AC;&#x2DC;pâ&#x20AC;&#x2122; from 1,500-3,800kN clamp force offers injection speeds of up to

350mm/s (500mm/s has been successfully tested with pilot customers). "

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eight injection units available, shorter set-up times and clamping forces up to 5,500 kN. â&#x20AC;&#x153;We are convinced that full electric solutions will take the lead in the next few years, especially for small and mid clamping forces,â&#x20AC;? said Professor Helmar Franz, CSO and a board member of Haitian International Ltd. â&#x20AC;&#x153;The principal market, Asia, has long set the pace, and the other markets will follow suit.â&#x20AC;?

Nearly 3000 Venus machines have been sold since its introduction in 2007, with the numbers virtually doubling each year.

The second generation is also available in the higher clamping forces of 3000, 3600, 4500 and 5500kN.

www.haitian.com Professor Helmar Franz, CSO of Haitian Intâ&#x20AC;&#x2122;l, believes that full electric solutions will take the lead in the next few years, especially for small and mid clamping forces 40

FEBRUARY / MARCH 2014

Haitian CEO Zhang Jianming started the group in 1966 and is still at the helm

EQUIPMENT

Cosmo Films (India) inaugurates ninth BOPP line COSMO FILMS, one of the worldâ&#x20AC;&#x2122;s largest producers of BOPP and thermal

locations in India as well as in South Korea and in the United States, inaugurated its

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packaging applications.

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FEB / MAR 2014

41

Control Cable protection systems for robots and

Robotics under control â&#x20AC;&#x201C; Robotec Systems manufactures robotic control cabling and

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CONTINUED automation of processes within the manufacturing industry in Southern Africa is fuelling demand for world-class robotics that will enable local companies to compete on a global stage.

Advanced control equipment that ensures the smooth operation of robotics out in

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the robotics to work ever faster and more accurately. Like the central nervous system of a living creature, signals are constantly transmitted between these controllers and robotic devices in order to facilitate effective operation of the processes.

In most manufacturing environments however, conditions are arduous, with extreme temperatures, excessive mechanical forces and sometimes chemicals and contaminants that can interfere with machines. As a result, careful attention needs to be paid to designing and manufacturing control cablings paths that can withstand the

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FEBRUARY / MARCH 2014

Uniloy Milacronâ&#x20AC;&#x2122;s latest all-electric blow moulding shuttle machine Power saving of 30-40% in comparison to hydraulic machines UNILOY Milacron Germany/B&W has added a new model to its all-electric machine line â&#x20AC;&#x201C; the UMS 20E.S. The machine

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joint arms onto both mould platens right into the centre of the pinch-off areas. Once the mould is closed no power is used.

Showcased during this yearâ&#x20AC;&#x2122;s K show, the machine produced 12 IT stackable UN containers including a view stripe. To achieve the highest product quality in the shortest cycle time with minimized use of resin and energy, the machine was

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30-40% in comparison to hydraulic machines was reported.

The general machine footprint is compact due to the integrated control cabinet underneath the extruder. Access to all machine areas is easy and safe for the operators.

Additional accessories such as a Delta quality centre including leak testing and weight control as well as an Eisbär blow air cooling system was part of the full line set-up.

Uniloy Milacron is represented by 444

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EQUIPMENT

your robot! handling systems Vital link Robotic cabling, harnessing and accessory specialists Helukabel, are at the forefront of technology to interface controllers with robots. The companyâ&#x20AC;&#x2122;s expertise ensures that the â&#x20AC;&#x2DC;central nervous systemâ&#x20AC;&#x2122; of an

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as it was designed to, for years to come no matter what conditions need to be contended with on site.

The companyâ&#x20AC;&#x2122;s Robotec Systems Gmbh subsidiary works with customers around the world who require robotic automation in their operations. Robotec engineers are able to develop pre-assembled cable

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robots and handling systems, as well as offer additional services to ensure the optimal performance of robotic systems for almost any application. The services they offer include system analysis, consulting, planning, installation, service and warranty of mass-produced cable protection systems for robots in automation systems.

Control pathways are tailor-made to suit customerâ&#x20AC;&#x2122;s applications with products that include dress package systems and associated systems for automation, handling, and spot welding, as well as gasshielded welding and laser welding.

Right solution Doug Gunnewegh of Helukabel South Africa says specialists are able to assist in the selection of the correct cables, lines, supplemental systems and cable protection systems to be used within all different applications. â&#x20AC;&#x153;They are able to conceive and construct suitable systems to keep pace with the ever advancing technologies used in robotics today. Whether in Germany, South Africa or anywhere in the world, Robotecâ&#x20AC;&#x2122;s expert team of robotics specialists is able to assist companies to get the most out of their automations systems

and keep them running reliably for years to come.

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FEBRUARY / MARCH 2014

43

Gamma Meccanica lines for recycling & â&#x20AC;&#x2DC;regradingâ&#x20AC;&#x2122; of PET

The Gamma Meccanica factory in Italy

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GAMMA Meccanica SpA of Italy has designed and manufactured machinery and lines since 1988 to recycle a wide variety of plastics, obtaining high quality pellets.

The companyâ&#x20AC;&#x2122;s G-Moby lines for the re-generation, re-grading and â&#x20AC;&#x2DC;super cleanâ&#x20AC;&#x2122; of PET, produces pellets suitable for food packaging in accordance with FDA and EFSA regulations, as well as

granules for applications that require high viscosity.

G-Moby works through two phases: the recovery of waste which is transformed into pellets, and a second phase where the pellets are heat treated using solid state polycondensation (SSP).

During the process the material

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agglomeration in a shredder unit, ensuring the complete evaporation of all water and the pre-melting of the material. The next step is the melting

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The result is PET granules or pellets

BĂźhler launches optical sorting station

44

FEB / MAR 2014

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THE BĂźhler Group, a global leader in optical sorting solutions, has launched the ground-breaking fully integrated Optical Sorting Station, bringing together the key elements of successful optical sorting, including plant engineering, sorting technology, pneumatic conveyors, pre-conditioners

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Building on 70 years of experience in optical sorting, BĂźhlerâ&#x20AC;&#x2122;s engineers have succeeded in delivering an integrated sorting station concept for plastics processors. This will mean that processors no longer need to

source separate elements from multiple suppliers, and manage multiple relationships. Â&#x2013;

sorting station features a purifying,

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Flakes can be fed into one end of the Station and collected at the other end â&#x20AC;&#x201C; ready for bagging or further processing.

Optical sorting station â&#x20AC;&#x201C; Multi-tier steel mezzanine, well-organised easilycontrolled and fully integrated into the plant

EQUIPMENT

with a very low intrinsic viscosity. "

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it eliminates any impurities present in the material (paper, wood, aluminum) and can be pushed up to the elimination of particles larger than 32 microns.

At this point the pellets, now cut and heated, are introduced into the G-Moby.

This device uses the principle of infrared treatment and vacuum up to 10-20 mbar, in a single step, crystallizing,

dehumidifying and operating the â&#x20AC;&#x2DC;super cleanâ&#x20AC;&#x2122; of the material. In this way, itâ&#x20AC;&#x2122;s possible to remove all the contaminants present in the PET, making it suitable for food use. Indeed, by merely increasing the residence time of the granule in the G-Moby, you can reach even higher degrees of IV of 0.9 dl/g. "

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used to â&#x20AC;&#x2DC;re-gradeâ&#x20AC;&#x2122; the material by using solid state poly-condensation, returning

material to the same mechanical and rheological properties that it contained in its virgin state.

G-Moby is available in a range of sizes with a production capacity of 80kg/h (with the smaller line GM50 COMPAC), to 2,200kg/h (with GM210 COMPAC).

Adex Plastics & Machinery cc represent Gamma Meccanica in SA.

www.adexplastics.com

The GM125 G-Moby Compac line with a production capacity of

www.gamma-meccanica.it

The GM50 G-Moby Compac. The larger lines (GM210 Compac) have a production capacity of up to 2,200kg/h FEBRUARY / MARCH 2014

45

11 new Laureates for the

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FEBRUARY / MARCH 2014 47

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.

Automotive

Electrical

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Packaging

Consumer

Compounding Service

Experience PR E MI E R P OL YM ER SOL UTION S w ith exten siv e A PPL I C A TION DEVEL OP M EN T and expert T E C H N IC A L SER VIC ES Visit www.plastamid.co.za for further information.

021I 914 9042 Johannesburg 922031 1600701 / Durban 3445 75 278 CPT 021Cape MEHTown MNHF JHB 011/ 922 1600 I 011 DBN 9546 I031PE762 08000

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MATERIALS

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contribute to processing improvement programmes both in virgin and recycled applications, according to Tim Cooper of Addivation in Johannesburg, the local supplier of SureFlo. The product is manufactured and supplied by Flow Polymers, Cleveland, Ohio. Flow Polymers has almost 30 years of experience in manufacturing compatibilizing additives, as well as a vast history of formulating hundreds of dispersions for all types of processes.

The product is already in wide use in the USA for production of black masterbatch, injection moulded

and rotational moulded articles and extrusions, including recycling. Cooper says SureFlo is only available in black currently.

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MATERIALS

From climate offender to useful material CO2 as a new source of carbon The test foams made from this substance are just as good as MORE than 30 billion tons of CO2 are released into the those produced the conventional way using only petroleum. atmosphere every year. But this greenhouse gas need no ;

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headed by Bayer have found a way to use carbon dioxide as a project manager Christoph GĂźrtler. A catalyst is required to set building block for premium plastics. the reaction in motion. In other words, the Christoph GĂźrtler carefully pours out a thick, CO2 has to be given a nudge, because it is crystal-clear liquid and tips a yellow chemical into it. Then he adds just a little water to the chemically inert and does not react readily on â&#x20AC;&#x2DC;Our ultimate goal is beaker, a couple drops of accelerant and gives its own with other substances. to manufacture it all a good stir. After a few seconds, a green Sustainable process a broad range of

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hardens: The experiment is a success! by the reaction. As a result, the entire process â&#x20AC;&#x153;This is a common foam,â&#x20AC;? GĂźrtler says.

is ecologically sustainable. Calculations â&#x20AC;&#x153;Weâ&#x20AC;&#x2122;ve now made ground-breaking progress containing no indicate that the new process requires less with the help of a new ingredient,â&#x20AC;? says energy in its life cycle and thus also emits less petroleum at all â&#x20AC;&#x201C; the Bayer researcher, holding up the glass CO2. thatâ&#x20AC;&#x2122;s our vision.â&#x20AC;&#x2122; containing the clear substance. â&#x20AC;&#x153;There is If the new process continues to produce an entirely new raw material in here: carbon good results, Bayer intends to start industrial dioxide.â&#x20AC;? #

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40 basic chemicals and more than 40,000 chemical products. â&#x20AC;&#x153;Large segments of the industry are already showing Substitute for petroleum

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54

FEBRUARY / MARCH 2014

NOW AVAILABLE IN SOUTH AFRICA

100 ton Servo machine in stock

KAWAGUCHI injection moulding machines are well known for their reliability and longevity.

This world-renowned brand is available in a variety of models.

KMB3 – servo and hydraulic KMB4 – servo and hydraulic KME – full electric machines All of these models use the KAWAGUCHI EZ8000 Hitachi controller with touch screen.

For more information contact Dave Moore on 083 675 8325 CALL NOW FOR YOUR QUOTATION, PRICES ARE COMPETITIVE!

*

Laser-markable compound aids development of innovative cable tie tool NEW Berlin Plastics, a custom injection moulding company, in the USA, was recently approached by HellermannTyton, a manufacturer of high-quality cable management products, for help producing an innovative cable tie tool it was developing.

The material needed to be strong enough for the small teeth on the toolâ&#x20AC;&#x2122;s plastic tension knob and be able to be imprinted with a graduated number scale. Berlin Plastics worked with custom compounder RTP Company to custom-engineer a laser-markable compound that met the tensile strength and printing requirements of the application.

New Berlin met with HellermannTyton to discuss the most effective and

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number scale to the toolâ&#x20AC;&#x2122;s tension knob.

HellermannTytonâ&#x20AC;&#x2122;s ideas included printing the numbers directly on the plastic, using in-mould decorating, or attaching a printed adhesive sticker. Based on their knowledge and experience, however, New Berlin business development manager, Dave Sansone and director of engineering, Mike Miller knew that none of these technologies were best for the application. â&#x20AC;&#x153;Weâ&#x20AC;&#x2122;ve both worked with RTP Company most of our professional lives, and knew of their ability to create laser-markable plastics that would also meet the strength and other requirements that this application demanded,â&#x20AC;? said Sansone.

Laser-marking the numeric scale was a much better solution, avoiding the time consuming challenge of printing, the high scrap rates that would have been associated with in-mould decoration, and the $

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small 6 mm wide sticker.

After careful testing and evaluation, RTP Company furnished a custom glass

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compound that provided the required tensile strength for the cable tie toolâ&#x20AC;&#x2122;s tension knob. A matched RTP 6042 Series thermoplastic elastomer (TPE) was then overmoulded on the knob to provide an ergonomic gripping surface. The TPE compound was formulated to bond with the rigid ABS substrate for optimum product integrity.

RTP Company colourists added lasermarking additives and colorants chosen for their compatibility with the ABS compound and the operational range of the laser being used. This allowed the laser to clearly â&#x20AC;&#x2DC;writeâ&#x20AC;&#x2122; an indelible, high contrast white mark on the black plastic surface.

www.nbplastics.com www.rtpcompany.com www.hellermanntyton.us

FEBRUARY / MARCH 2014

57

QUADRANT Engineering Plastic Products (EPP) has updated its range of food grade plastics in line with the new European Union Regulation (EU) 10/2011. The move makes ÂŞ #

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stock shapes with food grade and traceability labels

MATERIALS

Broadest range of EU 10/2011 compliant stock shapes for food industry

MATERIALS

Hollow but hefty Expanded Ultramid product line for water-injection technology (WIT) BASF is expanding its assortment of polyamide grades that have been optimized for the use of water-injection technology (WIT) in injection moulding.

The new WIT grades are UltramidÂŽ A3HG6 WIT Balance and UltramidÂŽ A3WG7 WIT. Thanks to water-injection technology, hollow plastic parts, for example, for medium-carrying lines that require a very good inner surface can be produced by injection moulding.

These two materials are now available in commercial quantities.

Resistant to water, oil and salt Owing to its improved hydrolysis resistance, the polyamide (PA) Ultramid A3HG6 WIT Balance is particularly wellsuited for components that carry coolant or that come into contact with water. At the same time, the content of PA 6.10 in this material also translates into high

stress-cracking resistance to calcium chloride, thus taking into account the more stringent requirements made in terms of resistance to road salt. Particularly in Asia, calcium chloride is often spread on icy roads.

In contrast, BASF recommends its new Ultramid A3WG7 WIT, which is reinforced

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that convey oil such as those employed for dipsticks, or else for other components that have to meet high demands in terms of oil resistance, stiffness and dimensional stability. Both materials lend themselves very well for WIT processing.

In the meantime, the hydrolysis-resistant basic product of the WIT series, namely, Ultramid A3HG6 WIT, has become the material of choice for many WIT applications such as cooling water pipes. www.ultramid.de

BASF has expanded its polyamide product line for pipes and tubes as well as other mediumcarrying hollow parts produced by water injection technology (WIT), a variation of the injection moulding process: whereas the new UltramidÂŽ A3HG6 WIT Balance is particularly hydrolysisstable and resistant to calcium chloride used as road salt, UltramidÂŽ A3WG7 WIT excels thanks to its improved mechanical properties and oil resistance, which means that it is primarily suitable for lines that carry oil.

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Target markets for Irogran CA117-200 include the automotive industry, the production of technical textiles, and the manufacture of footwear and sports equipment. Film adhesives based on Irogran CA117-200 offer good chemical and heat resistance. They also have a non-tacky surface and can be used without the need for a carrier or release liner backing.

(PHOTO MILLIKEN, MKPR094, COPYRIGHTŠ 2013 MILLIKEN & COMPANY, ALL RIGHTS RESERVED)

New thermoforming PP offers excellent aesthetics POLYCHIM is setting a new benchmark in the performance of homopolymer polypropylene (PP) in packaging applications with the launch of a new thermoforming PP offering excellent aesthetics, high quality and faster throughput to converters. Polychimâ&#x20AC;&#x2122;s HyperformÂŽ HPN-600ei enables thermoformers to produce high quality parts with excellent aesthetics at high output rates. Hyperform HPN-600ei stimulates an improvement in the aes

transparency and reduced yellowing for thermoformed goods compared to traditional nucleated homopolymers. As a result, new grade HA31XTF outperforms Polychimâ&#x20AC;&#x2122;s previous conventional nucleated homopolymer for thermoforming through better haze and less yellowing.

HA31XTF offers balanced physical properties, including favorable stiffness/impact balance and isotropic shrinkage behavior that avoids warpage. The combination of Polychimâ&#x20AC;&#x2122;s resin technology with the high crystallization temperature and isotropic shrinkage behavior provided by Millikenâ&#x20AC;&#x2122;s Hyperform HPN-600ei nucleator also gives the possibility for thermoformers to improve productivity by up to 10% and reduce costs. www.millikenchemical.com www.polychim-industrie.com

58

FEBRUARY / MARCH 2014

MATERIALS

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of oxo-biodegradable plastics outweigh compostables Essential conditions for composting of bio-plastics do NOT EXIST in SA

BY GEORGE FEE SELF DESTRUCT PLASTICS, DURBAN

THERE are two kinds of degradable plastics, hydro-degradable such as bio-plastics (typically starch-based products) and oxo-biodegradable (derived from the by-products of the oil

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Vestamid bio-based polyamides from

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Castor beans form basis for VestamidÂŽ Terra range The bio-plastics specialist FKuR Kunststoff GmbH is to market, sell and distribute Evonikâ&#x20AC;&#x2122;s full line of bio-based polyamide VESTAMIDÂŽ Terra products worldwide. Vestamid Terra polymers are partially or entirely based on renewable feedstock. The raw materials are the castor bean (Ricinus Communis) and its oil derivatives, which are synthesized into monomers which form the basis of the Vestamid Terra product range. Three grades of the material are currently available. Due to their excellent chemical resistance, low water absorption, and good dimensional stability, Vestamid Terra polyamides are suitable for a large number of applications

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60

FEBRUARY / MARCH 2014

Ford F-150 gets new look thanks to plastics PLASTICS are about to give Ford Motor Co.â&#x20AC;&#x2122;s iconic F-150 truck a distinct design signature. The all-LED headlight includes an acrylic light pipe around the lamp, which sets off the all-plastic system and makes the F-150 look like no other truck on the market, even in the dark. â&#x20AC;&#x153;It is a new design language,â&#x20AC;? said Gordon Platto, chief designer of the F-150, in an interview following the truckâ&#x20AC;&#x2122;s introduction at the North American International Auto Show in Detroit in January. â&#x20AC;&#x153;It gives a unique character to the truckâ&#x20AC;&#x2122;s front end, especially at night.â&#x20AC;?

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Ford began by developing a large headlamp package. Originally, the company had planned to use glass for the optics to focus the beam, but it could not achieve the needed clarity, so instead turned to polycarbonate.

The all-LED headlight on the 2015 Ford F-150 includes an acrylic light pipe around the lamp, which sets off the all-plastic system

DUPONT SurlynÂŽ was used to magnify and protect the red poppy embedded in the cap of â&#x20AC;&#x2DC;Flower in the airâ&#x20AC;&#x2122;, the most recently launched perfume from Kenzo.

The new technology involves the overmoulding of a container wrapped in textile with glass-like transparent Surlyn resin. This unique encapsulation process protects even the most fragile of materials such as lace, during the injection moulding process.

Objects, images, design elements and now even textiles can look as if they are suspended in a crystal-clear cap. The overmoulded decorations

www.dupont.com show no distortion

Coloured PC from Bayer helps the dentist!

A SPECIAL light probe now enables dentists to quickly recognize the extent of a cavity in a patientâ&#x20AC;&#x2122;s tooth and selectively remove it. The examination using the small, slim Facelight light probe from W&H Dentalwerk BĂźrmoos GmbH is based on a simple principle: The bacteria that cause cavities leave #

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A special light probe now enables dentists to quickly recognize the extent of a cavity in a patientâ&#x20AC;&#x2122;s tooth and selectively remove it. The small, slim Facelight light probe from W&H Dentalwerk BĂźrmoos GmbH is equipped with a specially coloured

polycarbonate MakrolonÂŽ LQ3187, which differentiates between the cavity and healthy tooth substance

FEB / MAR 2014 63

PRODUCTS

Illusion or reality?

WEB NEWS

Online store for hot runner components A NEW online store promises to permanently change the way operators of hot runner control systems purchase new or spare cables and connectors.

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Alfa Gama goes live

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automatic dosing machines. www.banbury.co.za/index.html

Intrinsys web seminar series THE journey in composites technology has witnessed a rapid evolution from a black art to a sophisticated industrial discipline. But is your knowledge up to date? Are you taking advantage of the latest technology or are you suffering from delays and errors in the design, analysis and manufacturing of 64

FEBRUARY / MARCH 2014

composite parts?

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Download and listen to experts explain and demonstrate innovations in the integration of composites $

draping simulation, composites tooling, operations intelligence for manufacturing and long-term archiving.

Architectural impression of Al Wasl Plaza in Dubai â&#x20AC;&#x201C; Dubai has been chosen as the site of the 2020 World Expo. The Expo is expected to draw more than 25 million visitors from October 2020 through April 2021

Middle East polymer industry will show more innovation & leadership as it matures By 2010 approx 7% of global polypropylene production will be in Midd

BY DR NIALL MARSHALL

FEATURE

THE oldest of the Middle East polymer companies, founded in the 1980â&#x20AC;&#x2122;s, are already out of their â&#x20AC;&#x2DC;teensâ&#x20AC;&#x2122;. But with much of the capacity growth occurring in the last ten years it is very interesting to consider how fast it has grown, and what is expected in the near future. "

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started producing polyethylene in the early 1980â&#x20AC;&#x2122;s. By the end of the decade there was still less than a million tons of polymers produced per year on three polyethylene plants in Saudi Arabia and one in Qatar.

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the region was commissioned in Saudi Arabia and during the decade all the $ $

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expanded. But by 1999 there was still less than 2 million tons of polymers produced in the Middle East including some PVC. Â&#x17E;

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capacity was in 2000 is illustrated by the fact that it produced about 2.5% of the worldâ&#x20AC;&#x2122;s polyethylene and only 0.5% of the worldâ&#x20AC;&#x2122;s polypropylene.

By 2010 the situation had changed

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establishment of new companies in Saudi Arabia, Qatar, Kuwait, Oman and the U.A.E added almost six million tons of polyethylene capacity and four million tons of polypropylene capacity â&#x20AC;&#x201C; approximately 7% of global polypropylene production was in the Middle East! Today there are almost 20 polymer producers in the region.

The growth in the polymer industry 66 FEBRUARY / MARCH 2014

from 2000 was driven by increased global demand for polymers. The favourable geographical location between Europe and Asia combined with the cost advantage of a raw material that would otherwise have

# #

location for global polymer producers.

Even during the economic slowdown from 2008 the cost advantages of large, modern plants in the Middle East were such that debottlenecking, expansions and new projects continued to be announced and completed.

Since 2010 there has been almost 3 million tons of new polyethylene capacity commissioned and a further 2.4 million tons of capacity will come on stream during 2015.

Some observers believe that constraints on oil-based feedstock supplies combined with the shale gas revolution in the United States as well as coal-to-chemicals investments in China will present challenges to the Middle East petrochemical industry and that there will be less investment in polymer plants in the future. This is undoubtedly true in some countries like the U.A.E and Kuwait, but the availability of natural gas and novel feedstock from the new

polymer plants will continue for the rest of the decade and there are at least

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scheduled to come on line by 2016.

The other challenge is where all the additional volumes of polymer will be sold.

There is increased local demand in the region with large infrastructure projects including airport expansions and railway projects in Abu Dhabi, preparations for the

le East

2022 Football World Cup in Qatar and the World Expo 2020 awarded to Dubai.

There will also be growth based on urbanization and the demands of a growing middle class in China and the rest of Asia, but there are also new polymer plants coming up in China, and so new markets will need to be developed. Net polymer importing regions such as West Africa and Latin America will become more important for Middle East producers.

Latin America has traditionally sourced polymer from the United States, but despite the number of new projects announced in North America it is expected that the booming US market will affect polymer availability in South America. Global markets will become more competitive and without large raw material cost advantages the Middle East producers have been accustomed to, they will be forced be more innovative.

The Middle East polymer industry has gone through a rapid growth spurt in the last ten years. However, there is still room for further growth which is expected to continue at least until 2020 as the industry becomes even more innovative and demonstrates more leadership as it matures.

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

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THE DESIGN FACTORâ&#x20AC;Ś

DESIGN

Design students showcase their best THE industrial design departments of both TUT and UJ held their annual student exhibition at the end of last year. Past alumni and industry are invited to see the range and quality of the

studentsâ&#x20AC;&#x2122; work which also allows for feedback.

These events are well attended by the industrial design fraternity.

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THE DESIGN FACTORâ&#x20AC;Ś

DESIGN

Design â&#x20AC;&#x201C; critical to growth of viable product manufacturing sector in SA & 8

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DESIGN and creativity has proven over and over again to boost manufacturing performance, in turn creating more demand for innovative thinking and the application of design in industry.

Northern European countries and the UK manufacturing and business sectors have put in place initiatives to compete aggressively against economic hard times. They have acknowledged with serious intent that in implementing a controlled professional product design and development

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opportunities.

In South Africa the need for the continued growth of a sustainable product manufacturing sector that will feed a domestic and export market with quality innovative products, is an area of major importance.

Each year two top South African institutions â&#x20AC;&#x2DC;produceâ&#x20AC;&#x2122; our countryâ&#x20AC;&#x2122;s next generation of industrial designers â&#x20AC;&#x201C; those creative minds that eventually mastermind the quality innovative products that make an extraordinary difference in our lives every day.

We spoke to Mike Wythe and Angus Campbell, each an industrial design fundi, about their views on the current state and future of industrial design in this country. Mike is an industrial designer and lecturer for the Industrial Design Programme at the Tshwane University of Technology (TUT).

Angus is a senior lecturer in the Department of Industrial Design, FADA, at the University of Johannesburg (UJ).

There appears to be an increasing interest in industrial design as a career. Competition is tough and only the best students are accepted at TUT & UJ. ` : Every effort is being made by the institutions to present industrial design as a career option. The main problem is exposure â&#x20AC;&#x201C; matrics from the â&#x20AC;&#x2DC;sticksâ&#x20AC;&#x2122; have had little exposure to

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70 FEBRUARY / MARCH 2014

The Joe Paine bird fold feeder (above) â&#x20AC;&#x201C; inspired by paper origami birds, the fold feeder subtly resembles a perched Giant Eagle Owl. Joe Paine is a product and furniture designing products that are inventive but simple, sophisticated without pretension, with a focus on outdoor applications, plants and bird life

come from. Those that do apply have a basic understanding of design, but this usually stems from their appreciation for fast, luxury cars â&#x20AC;&#x201C; most applicants want to be car designers!

However, over the last four years TUT have seen a developing interest in the course we offer, together with an improvement in the quality of applicants, so something positive is happening!

Angus: With the ease of access to information through mass media, potential students and school leavers are becoming more exposed to the realm of industrial design. With organisations such as the SABS Design Institute, Southern Guild, Design Indaba and with Cape Town being awarded World Design Capital 2014, design is also being documented much more thoroughly in the popular press. This exposure is also increased for scholars with the inclusion of design and technology as a possible matric subject. Our department # Y::

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half of the 200 do not meet minimum requirements in terms of their marks, but the rest are required to submit a portfolio which allows us to evaluate the range of their skills and their understanding of the profession. Competition is tough and only the best students are accepted.

For many students, the initial attraction of an industrial design degree is automobile design! ` : The initial interest in industrial design is usually developed from an interest in cars. Evidence presented in the portfolios submitted by applicants shows that the majority believe cars have been â&#x20AC;&#x2DC;designedâ&#x20AC;&#x2122;, while other products (electrical appliances, white goods, cell phones, etc) are â&#x20AC;&#x2DC;just madeâ&#x20AC;&#x2122;. This undeveloped understanding of what design is all

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THE DESIGN FACTORâ&#x20AC;Ś >> is far more to design than meets the eye.

Angus: There is a serious love affair with automobiles in South Africa and for many of the students entering our programme, a degree in industrial design is a stepping stone to an international

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With the rise of Apple, the popular understanding of what industrial design can achieve also attracts creative students towards the discipline, although there are still a lot more parents who would like their children to be engineers, lawyers or doctors!

Industrial design graduates typically become entrepreneurs, or work as part of a design team, product manufacturer, model maker or illustrator. ` : Employment is at the forefront of the studentâ&#x20AC;&#x2122;s mind. Opportunities within the consultancy sector are few and

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in SA as yet has not recognised the valueadded contribution design can make to their endeavours; the manufacturing SME sector in SA is still in its infancy and therefore the demand for design input is limited. As students progress through the course over three years,

they do begin to focus on the idea of becoming entrepreneurs as they see the real possibilities in designing, making and distributing their own products.

Angus: Both our 3rd (NDip) year and 4th (BTech) year students undertake internships during their three years of study. These internships regularly result in our students having jobs waiting for them before they graduate. The great news is that this year the demand for industrial designers in a range of industries has been staggering! Graduates typically enter the following career paths: as a member of a design team at a design consultancy; as a member of an inhouse design team at a manufacturing company; as a manufacturer of products; as a model maker or as an illustrator.

However, the process of design thinking taught to our students can be applied in a wide range of careers and the breadth of

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National industry competitions ensure students are exposed to reallife commercial design needs. ` : All students have the opportunity to participate in factory visits which give the

students a direct insight into the various manufacturing and production processes that are out there. Injection moulding, sheet metal fabrication, pressing, forming #

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Z hand. Students are encouraged to enter industry related projects and competitions, for instance, the Sasol & ARMSA student product of year competition, the PISA, & " Â&#x201C; # & Âł*+

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competitions, and Eskom lighting and COBRA tap design projects.

Taking part in these competitions students have to address issues beyond those of mere aesthetics. They have to prepare manufacturing documentation #

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product costing information. They have to prepare a package of information that will communicate the marketing aspects (aesthetics, function, ergonomics) of their product, as well as all the manufacturing #

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required to move into volume production.

Angus: Our department tries to make sure that all projects undertaken by students are as real as possible, but

of manufacture. In the 1st and 2nd year of the programme our training focuses on teaching skills. In 2nd year the students

72 FEBRUARY / MARCH 2014

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participate in multiple national industry competitions (such as the ARMSA and PlSA student design competitions), and in 3rd (NDip) and 4th (BTech) years students regularly undertake projects for international competitions and local industry briefs. Many of the projects they undertake also require them to outsource certain components of their designs to manufacturers (such as laser cutting) which stands them in good stead should they want to start their own companies directly after graduating.

Design must be taken seriously as an integral part of manufacturing, business development, growth and increased employment. ` : I believe there is a growing interest in industrial design within the manufacturing sector. Within small, medium and large company structures there should be a genuine acceptance that â&#x20AC;&#x2DC;the design factorâ&#x20AC;&#x2122; is a strategic business tool that can have a major impact on your companyâ&#x20AC;&#x2122;s bottom line.

If we, as a developing country, are to see any improvements in our balance of payments or GDP we must start manufacturing value added products.

To give industrial design just a passing glance as a â&#x20AC;&#x2DC;nice to haveâ&#x20AC;&#x2122; is not good enough.

Angus: The plastics industry in Â&#x17E; @& Âł*+ &B*+

ARMSA and Afrimold) has been very good at running annual competitions with our students, exposing the students to the industry and the industry to the creativity of the students. In terms of relevance and quality, for all exit level modules we have industry based moderators that give us feedback on the student work and project briefs.

Through our annual student exhibition past alumni and industry are invited to

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see the range and quality of our student work which also allows for feedback.

There are a number of hurdles for the industrial design graduates who hope to follow an entrepreneurial route. However, starting small, whilst keeping overheads low and gradually building the company has given birth to some great success stories. ` : There is no easy access to venture capital to set up their operation.

If it is self-funded it is heavily taxed from the start, putting a burden on cash

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from ex-factory to distribution to retail is

ups are high. Local tooling costs are not competitive and local raw material costs are high. There is also little or no promotional initiative for locally designed and manufactured products.

A â&#x20AC;&#x2DC;shop windowâ&#x20AC;&#x2122; for South African designed and made products would be a great help â&#x20AC;&#x201C; a South African Design Centre!

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ability to protect your design whilst

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the greatest challenges for students trying to commercialise their designs.

However, many alumni have started very successful commercial enterprises straight out of university. These tend to be students that start small, whilst keeping overheads low and gradually building their company through their success. Examples of such companies are Dokter and Misses, and Joe Paine who both recently returned from exhibiting their design work in London and New York to much praise.

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How to build a cohesive

leadership team A model for building high performing teams WITH so many books and articles having been written about it, and so many experts having talked about it for so long, teamwork should not be as rare as it is in todayâ&#x20AC;&#x2122;s organisations. But that is the reality.

Most of the organisations where we live and work are marked by underperforming, often dysfunctional teams.

Why? First, the term teamwork has been overused and has lost much of its meaning. Second, people over-complicate teamwork. The fact is teamwork is simple â&#x20AC;&#x201C; in theory, anyway. Most of us already know what it requires. But in

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because human beings are messy, fallible creatures, and when you put enough of us in a room and ask us to work together, problems arise.

To overcome those problems, teams

energy, and discipline. For those teams willing to do what it requires, the rewards are great.

Functional teams make higher-quality decisions and accomplish more in less time, with less distraction and frustration.

Furthermore, they avoid wasting time talking about the wrong issues and revisiting the same topics over and over again because of lack of buy-in.

Addressing the dysfunctions Additionally â&#x20AC;&#x2DC;Aâ&#x20AC;&#x2122; players rarely leave To begin improving your team and to organisations where they are part of a better understand the level of dysfunction cohesive team. you are facing, ask yourself these simple Facing dysfunction and focusing on questions: teamwork is particularly critical at the top of an organisation because the executive Do team members openly and readily team sets the tone for how all employees disclose their opinions? work with one another. Without effective Are team meetings compelling and teamwork at the top, without a cohesive productive? group of people leading an organisation, Does the team come to decisions a company cannot begin to tap into the quickly and avoid getting bogged down potential that it has in any other area. by consensus?

A founder of a very large company best Do team members confront one another expressed the power of teamwork when about their shortcomings? he said, â&#x20AC;&#x153;If you could get all the people

in the organisation rowing in the same interests for the good of the team? direction, you Although no team â&#x20AC;&#x2DC;Without a cohesive group could dominate is perfect and even any industry, of people leading an the best teams in any market, sometimes struggle organisation, a company against any with one or more of cannot begin to tap into the competition, at these issues, the potential that it has in any any time.â&#x20AC;?

Fortunately, other area.â&#x20AC;&#x2122; constantly work to there is hope. ensure that their answers are â&#x20AC;&#x2DC;yesâ&#x20AC;&#x2122;. If you Counter to conventional wisdom, the answered â&#x20AC;&#x2DC;noâ&#x20AC;&#x2122; to many of these questions,

#$

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your team may need some work. and curable. However, making a team The 5 dysfunctions of a team functional and cohesive requires levels of "

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courage and discipline that many groups and confusion within your team is to cannot seem to muster. # #

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to contend with, and each must be addressed, separately and as part of the whole.

Dysfunction #1: Absence of trust This occurs when team members are reluctant to be vulnerable with one another and are unwilling to admit their mistakes, weaknesses or need for help.

Without a certain comfort level among team members, a foundation of trust is impossible. @

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Teams that are lacking in trust are incapable

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about key issues, causing situations where

74 FEBRUARY / MARCH 2014

FEATURE

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discussions and back channel comments.

In a work setting where team members do not openly air their opinions, inferior decisions are the result.

Dysfunction #3: Lack of commitment ;

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members to commit to decisions, creating an environment where ambiguity prevails.

Lack of direction and commitment can make employees, particularly star employees, disgruntled.

Dysfunction #4: Avoidance of accountability When teams donâ&#x20AC;&#x2122;t commit to a clear plan of action, even the most focused and driven individuals hesitate to call their peers on actions and behaviours that may seem counterproductive to the overall good of the team.

Dysfunction #5: Inattention to results Team members naturally tend to put their own needs (ego, career development, recognition, etc.) ahead of the collective goals of the team when individuals arenâ&#x20AC;&#x2122;t held accountable. If a team has lost sight of the need for achievement, the business ultimately suffers.

In a nutshell, team members who

commit to decisions and hold one another accountable are very likely to set aside their individual needs and agendas and focus almost exclusively on what is best for the team. "

Make sure you hire people who are capable of being strong team players. "

#

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culture, be committed to the team and be capable of being genuinely vulnerable and

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make teamwork an ongoing priority, not just a slogan. Front load the team-building process by scheduling a meaningful offsite gathering. But remember, effective teambuilding has to be done in the context of real work, not tree climbing exercises.

Team-building exercises have to be grounded in the realities of doing our jobs.

Thatâ&#x20AC;&#x2122;s what makes the team-building process stick.

The rewards Striving to create a functional, cohesive team is one of the few remaining competitive advantages available to any organisation looking for a powerful point of differentiation.

Successful teamwork is not about mastering subtle, sophisticated theories, but rather about embracing common sense with uncommon levels of discipline

and persistence. Ironically, teams succeed because they are exceedingly human. By acknowledging the imperfections of their humanity, members of functional teams overcome the natural tendencies that make teamwork so elusive.

How long does it take to build an effective team? It depends. If a team works together over a relatively short period of time, they can achieve this kind of team dynamic in a matter of weeks. But that means they talk about being a team, both in terms of interpersonal dynamics and

#

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some teams can work together for years and still be dysfunctional, and others can come together over the course of a month and become remarkably cohesive.

Finally, building a team is a process that never ends. It requires a constant investment of time and energy. It is also not a virtue, but a strategic choice â&#x20AC;&#x201C; a

purposeful decision that organisations make. For those leaders willing to make this choice and to make teamwork a priority, they will enjoy a powerful competitive advantage that is essential for maneuvering in todayâ&#x20AC;&#x2122;s marketplace.

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76 FEBRUARY / MARCH 2014

CATEGORY WINNER: Chassis/Hardware

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to an accident scene. Specially formulated resin is free of styrene emissions, making it safer for workers and the environment.

Selective pattern layups allow for localized reinforcement. The application also features a large structural joint of composite to steel.

CATEGORY WINNER: Materials

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FEBRUARY / MARCH 2014 77

WORLD NEWS

CATEGORY WINNER: Powertrain

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OEM Make & Model: 2011 Audi AG Audi A4* & A5* sedans with 2.0L TDI & TFSI engines Tier Supplier/Processor: RĂśchling Automotive

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assembly has been designed to be both the mounting surface for the seat side airbag (SAB) as well as integral to the performance and cosmetic function of the cover. This unique design answered the challenge of meeting styling studio requests for a thin seat appearance, but providing packaging space for increasingly large side airbags, which now typically 78 FEBRUARY / MARCH 2014

protect occupants from chest to pelvis. The

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WORLD NEWS

Plastic balls protect California reservoirs 80 million balls will blanket LA Reservoirâ&#x20AC;&#x2122;s surface Âľ Â&#x153;Â&#x153; $

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Faurecia boosts automotive bioplastics Injection moulded bio-composite combining hemp and polypropylene

80 FEBRUARY / MARCH 2014

AUTO supplier Faurecia SA has launched production of an injection moulded bio-composite combining hemp and polypropylene in Europe, and is looking for opportunities to expand the technology to North America.

At the same time, the company is in development on an all-natural composite which would combine natural

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developments come as the auto industry looks to reduce weight and decrease

traditional materials.

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moulding material, which can be used on existing equipment, decreasing the costs of bringing it to market.

The company began making door panel substrates with it during the summer for two parts on the PSA Peugeot Citroen Groupâ&#x20AC;&#x2122;s Peugeot 308.

Hemp also offers an improved density level over glass or talk, so Faurecia can produce a thinner walled part with the same structural capabilities. In the case of the Peugeot 308, it is saving 400 grams per door panel.

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especially instrument panels, and is looking at beginning production in the The Peugeot 308 uses an injection moulded biocomposite substrate, supplied by Faurecia SA, in the door panels

The Los Angeles Department of Water and Power is using millions of four-inch polyethylene balls to cover reservoirs to prevent a potentially dangerous chemical reaction from happening

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The shade balls cut down the amount of light, which reduces the amount of algae that can grow, and that reduces the use of chlorine needed to control algae. They also keep the seagulls and migratory birds off. www.xavierc.net

Amcor partners with private label manufacturers U.S. It is lining up material suppliers as well, including sources for hemp.

In testing, hemp has been the best natural material for bio-composites because it works best with the PP chemistry, although U.S. laws restrict hemp production in the country. Other companies have sourced hemp from Canadian farmers for compression moulded parts. "

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AMCOR Rigid Plastics is playing a leading role in the development of private label products for the food and beverage industry by delivering innovative and unique package designs to help retailers build brand equity and expand market share. The company showcased its industry-leading capabilities #

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FEBRUARY / MARCH 2014 81

AROUND THE WORLD NEWS WORLD

machine warehouse in China

Ascend launches new compounding operations in Pensacola, Florida ASCEND Performance Materials Inc., a leading producer of PA66 resin and chemical intermediates, is starting a new compounding line in Pensacola, Florida.

Ascend produces PA66 resin in Pensacola, Florida, and in Greenwood, SC. Since 2005, Ascend has more than doubled its resin capacity, primarily in Pensacola, Florida making it one of the largest PA66 resin producers in the world. In recent years, Ascend has also invested capital and resources to expand production of VydyneÂŽ compounds.

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Pensacola, Florida. The new line adds state-of-art capabilities for producing

unique, high-performance compounds.

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applications with intricate part geometries. www.ascendmaterials.com

Plastic to keep World Cup cool in Qatar

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www.arburg.com

Clariant to acquire Indian masterbatch producer Â&#x153;+Â&#x2DC;B+Â&#x201E;"

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will be introduced to offer the market highly innovative and customized products. www.clariant.com

82

FEBRUARY / MARCH 2014

Dow Chemical to separate chlorine business PVC is at the heart of a showcase stadium design that was part of Qatarâ&#x20AC;&#x2122;s bid for the 2022 FIFA World Cup. The proof-of-concept, 500-seat structure, was constructed in just

4 4 " multi-skinned roof structure is clad with screens of triangulated PVC fabric supported on a secondary steel frame, with an inner cladding of triangulated â&#x20AC;&#x2DC;pillowsâ&#x20AC;&#x2122; of translucent membrane, keeping radiant and conductive heat out and allowing natural lighting into the arena. Its canopy roof rotates, in 14-and-a-half minutes, to provide shade within the building and insulation against the hot sun in summer. According to Arup, the London

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The venuesâ&#x20AC;&#x2122; solar panels will operate year-round, continuously exporting electrical energy to the national grid.

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chlorinated organics and brine operations.

In October, Dow sold its polypropylene licensing and catalyst business to W.R. Grace & Co. for $500 million. That sale included a PP catalyst plant. www.dow.com

BOOKS

Unmet Needs in Plastic Electronics SMITHERS Rapra has published a new title forecasting the near future for plastic electronics.

Plastic electronics is poised to enter and irrevocably change a number of large markets. With more than 1000 companies already in the sector, the supply chain is complex, fast-growing and dynamic.

Forecasts for the next decade rely on successful deployment of a range of processes and materials. â&#x20AC;&#x2DC;Unmet Needs in Plastic Electronicsâ&#x20AC;&#x2122; #

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at drivers and challenges shaping the industry. The report also breaks down the world plastic electronics markets by material and manufacturing process, end use and geographical region.

With strategic forecasts to 2018 this is the essential report to keep your business up to speed.

The volume includes: â&#x20AC;˘ details of the drivers shaping the future of the plastic electronics technology industry, including displays, solar cells, functional inks, automotive and other applications; â&#x20AC;˘ latest market data detailing global printed electronics markets by material and manufacturing process, end-use and Numerous new applications are emerging for plastic electronics region, with strategic forecasts to 2018; and The only downside of the book is the â&#x20AC;˘ analyses of end-use markets, cost, itâ&#x20AC;&#x2122;s selling at a rather steep ÂŁ3555. technology trends, and emerging regulations you can use in business www.smithers.com planning.

Polymers in cables ACCORDING to â&#x20AC;&#x2DC;Polymers in Cables â&#x20AC;&#x201C; the European Marketâ&#x20AC;&#x2122;, an industry study performed

by Applied Market Information Ltd. (AMI Consulting), in 2013 the European market for cables was worth circa â&#x201A;Ź20 billion. Expressed in terms of plastic compound-on-the-cable, this market lost circa 15% of its 2007 peak volume.

However, the performance has not been uniform â&#x20AC;&#x201C; some regions performed considerably better than others. +¤B

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compete. This is likely to result, in the following years, in deep structural changes in the industry. www.amiplastics.com 84 FEBRUARY / MARCH 2014

Global market for polystyrene

Market Study: Polystyrene

MARKET research institute Ceresana has revealed that revenues for global polystyrene market are likely to rise to approx. US$26 billion in 2020.

Almost every second ton of polystyrene is processed in Asia&

market, followed by the industrialized regions North America and Western Europe. Ceresana forecasts the focus of polystyrene demand to continue

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industrialized markets in North America and Western Europe.

In the past, capacity utilization of polystyrene plants averaged at only about 75%. This resulted in an, in part, considerable reduction of capacities and restructuring undertaken by manufacturers. Industrialized countries in Western Europe and North America as well as Japan and South Korea have responded to the excess capacities by reducing production volume and refocusing on growth markets.

To satisfy the rising global demand production capacity has to increase. Hence, the global production capacity will be expanded by about 700,000 tons until 2020. More than 90% of

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The report provides information on demand, revenues, and production. Data on existing and future production capacity is also provided. It also examines the 20 largest countries of the market in more detail and provides information on demand, revenues, production, import, and export of polystyrene as well as current and future capacities. The analysis of demand for polystyrene is examined in detail split by packaging, electrical & electronics, and other applications. www.ceresana.com/en/Market-Studies/Plastics/Polystyrene

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DIARY

Label Summit Africa in March Global labels show comes to Cape Town THE Labelexpo Global Series hits South Africa again when the Label Summit Africa is presented at the Cape Town International Convention Centre on 10-11 March.

The event is part of an on-going international series of conferenceexhibitions which includes events later this year in Latin America, Indonesia, America, India and China. That in itself provides a springboard for delegates to learn more about label technology and dynamics in other packaging markets globally.

The conference programme on Monday 10 March starts with an analysis of the global and local label market by Filip

Weymans, director for segment marketing and business development, labels and packaging at Xeikon.

That is followed by a programme with local and international speakers from suppliers including Self Adhering Products, Collotype Labels RSA/Multi-Color Corporation, Accraply Inc, CGP-ETIQROLL and CODIMAG. The dayâ&#x20AC;&#x2122;s programme concludes with an â&#x20AC;&#x2DC;African converter panel discussionâ&#x20AC;&#x2122; moderated by Andy Thomas-Emans of Labels & Labeling and featuring Leon Witbooi, MD of SA Litho; Uwe BĂśgl, MD of RAKO labels; George Pryde of LithoChrome (Nigeria); and Peter Frost of

Associated Printers (Zambia). A networking reception and dinner follows.

Day 2 has a half-day programme with a more local slant, the speakers being Gill Loubser of Packaging & Print Media publication; Bill Marshall of Syndicate Graphics (also coordinator of the Gold Pack Awards programme) and Mark Anley of Indigo Brands.

It also features a â&#x20AC;&#x2DC;brand and retailer panel discussionâ&#x20AC;&#x2122; which includes a representative from Clicks, and culminates with a look at how to revolutionise branding and design

by Mike Taberner of Brandesign. www.labelexpo.com

Food & drink technology Africa in March FOOD & drink technology Africa, a new event organised by Messe MĂźnchen International and its subsidiary MMI South Africa, will premier on 18-19 March at the Gallagher Convention Centre in Midrand. "

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reliable machinery and plants, the local and international exhibitors at fdt Africa can provide exactly this.â&#x20AC;?

A conference will run in parallel with the exhibition, with open (free) and closed (participation fee required) sessions.

Day one of the open sessions will feature exhibitor presentations by Buhler, Hosokawa-Bepex, Chocotech, Bosch Packaging, Multivac and GEA Processing

Engineering. These sessions will cover

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Day two of the open sessions features presentations by the Brewers Association of Europe, Pentair, Krones and GEA Process Engineering. The topics for day two include sustainable brewing solutions

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Global event Drinktec is a major international show.

Drinktec 2013, which took place in Munich from 16-20 September 2013, attracted 1,433 exhibitors from 77 countries and 66,886 trade visitors from 183 countries. processing, water minimisation in the food and beverage industry and strategies for responsible use of plastic packaging in the food industry will be covered by institutions and companies including the University of Pretoria, Anelich Consulting, VDMA NuV Germany, Andrew Murray Consulting and Plastics SA. Visitor and conference registration for the event can be completed online.

Closed sessions The closed sessions will look at hygienic,

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food and beverages. Topics including food security in South Africa, www.drinktec.com energy in South African food

www.fdt-Africa.com

Incoe innovations AT Euromold 2013 in Frankfurt, the hot runner system manufacturer Incoe International Europe, of RĂśdermark, Germany, introduced innovations, concepts and solutions with advances in miniature hydraulics and fast colour change.

HEM miniature hydraulics offers proven performance with a compact footprint approx. 50% less when compared to conventional hydraulic cylinders. For multi-cavity moulds, the mould maker can now increase cavitation allowing processors to produce more parts without the need for increased machine size.

In the automotive area, frequently large moulded parts, such as door trim panels require large hot runner systems custom designed to the geometry of the unique moulded part produced.

Where needed, the designer can now realize injection points that are situated very close together. The latitude for selection of the injection points is broader overall, and this facilitates the positioning 86 FEBRUARY / MARCH 2014

of slides and ejectors. The smaller milling areas strengthen tool stability for repeatable moulding of parts.

HEM â&#x20AC;&#x201C;Reliable, sturdy and with the greatest design latitude possible: miniature hydraulics and screwed-in nozzles make this possible

www.incoe.com

Freeformer impresses again at Euromold High level of interest in additive manufacturing INTEREST in the Arburg Freeformer and its innovative technology was phenomenal among the plastic processing community at its world premiere at K2013 in DĂźsseldorf in October last year, and that success continued at Euromold in December where itâ&#x20AC;&#x2122;s technology was appropriate because of its association with additive manufacturing and 3D printing.

The potential of the Freeformer and of Arburg Plastics Freeforming (AKF) was demonstrated with two exhibits which produced different one- and two-component parts from standard material at the stand.

Additive manufacturing reinvented With the AKF process, it is standard granulates, rather than special resins, powders, strips or other prefabricated materials which are melted and processed. This means that a wide selection of materials and colours is available. "

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required.

The Freeformers are mobile and universally usable thanks to their compact dimensions and immediate production readiness.

The machines are simply connected to the power supply and production can begin straight away. www.arburg.com " ~

4

and small-volume batches as well as complex 3D geometries and movable â&#x20AC;&#x2DC;hard-softâ&#x20AC;&#x2122; combinations

JEC Europe THE JEC Europe Composites Show takes place in Paris from 11-13 March JEC Europe is the leading platform for the global composites industry. Two out of three visitors are users of composite solutions: Buyers from the end-user sectors, such as engineering or R&D departments, designers and manufacturers in the main application sectors.

The strong informational content of JEC Europe also attracts researchers, universities and trade associations.

Last yearâ&#x20AC;&#x2122;s show saw 1,204 companies from all over the world exhibit and attend business meetings and conferences from all

#

$< The production of composite components from the wide range of materials In 2014 the JEC Europe Show and Conferences will focus on available as well as, increasingly, new production technologies is at the the development of the composites industries in the Netherlands. heart of the JEC show. Here we see a technician at BMW in Germany Combined with the Dutch aerospace industry and its strategically involved in the production of parts for the LifeDrive concept vehicle, in located cluster with over 100 companies, the Dutch high-tech which they are developing an â&#x20AC;&#x2DC;architectureâ&#x20AC;&#x2122; to reduce the vehicleâ&#x20AC;&#x2122;s weight and accommodating the battery, which requires additional space systems and materials sector bolsters innovations in the areas of high-tech equipment, components and www.jeccomposites.com/events/jec-europe-2014 materials.

FEBRUARY / MARCH 2014 87

COMING UP MAIN PULTRUSION EVENT IN MARCH

ARABIAMOLD IN APRIL

THE 12th World Pultrusion Conference takes place in Lisbon, Portugal, on 6-7 March 2014. Held every two years, the event is organised by the European Pultrusion Technology Association (EPTA). Twenty-one speakers from around the world will offer practical presentations with up-to-date information of innovative applications for pultruded reinforced plastics. www.pultruders.com

PART of the global series of mould shows presented by Demat of Germany, ArabiaMold, takes place in Sharjah, United Arab Emirates, from 7-10 April. ArabiaMold 2014 together with Plastivision Show 2014, which were launched concurrently in 2012, will cover an exhibition area of 10,000m² and feature exhibitors from over 20 countries and the whole process chain from ‘idea to series production’. www.amiplastics.com

JEC COMPOSITES SHOW GETS BIGGER JEC Europe, the global composites show, will be 8% bigger this year, occupying 54,400m² at the Porte de Versailles in Paris from 11-13 March.

The last edition of JEC attracted close to 28,000 delegates from 1204 companies, with a fairly large group from the sector in South Africa travelling to the show. The sectors where composites appear to be generating most applications in SA at present include construction and mass transport, although the yacht building market was for long the main activity. www.JECcomposites.com

88 FEBRUARY / MARCH 2014

PROPAK EAST AFRICA IN APRIL THE PROPAK East Africa show takes place at the Kenyatta International Conference Centre in Nairobi, Kenya, from 1-3 April. This is a new event for East Africa, introduced by the organisers of Propak Africa, and will be the first truly international platform for goods and packaging manufacturers to promote products and services to an international audience as well as for other African manufacturers to explore opportunities in the region.

VDS Media, the Johannesburg specialist conference organiser, will present a conference on day 2 of the show which will focus on the East African packaging, printing, plastics and converting industry.

Developments in this value chain, encompassing packaging materials, suppliers, labelling, converting equipment, flexographic and offset printing and market trends will be the highlighted. www.propakeastafrica.com www.vdsmedia.co.za

‘EVOLUTION OF SUSTAINABILITY’ AT CHINAPLAS IN APRIL ONE of the features of this year’s edition of ChinaPlas – in Shanghai from 23-26 April – is sustainability. Echoing the increasing demand for more sustainable business practices, the Chinese show will promote sustainability under the theme of ‘Greenovation: Solution to Sustainability’.

A ‘City of Tomorrow’ event will feature a circular shape structure at Central Square of the exhibition centre to showcase a sustainability model which covers the sustainability concept in terms of Alternative Raw Materials, Energy-efficient Machinery, and Recycling.

Then a 2-day Green Conference – co-hosted hosted by Adsale Exhibition Services, Plastics Information Europe (PIE) and the Association of Green Molding Solutions (AGMS) – will feature ‘Innovative Solutions for Plastic Recycling’ and ‘Green Molding to Halve the Cost and Double the Wealth’ sessions. www.ChinaplasOnline.com

LOWER OLEFINS SYMPOSIUM THE International Institute for Synthetic Rubber Producers (IISRP) and the American Chemistry Council’s Olefins Panel are to present an international symposium on ‘Health Risks of Lower Olefins’ in Austin Texas on 25-26 June. Five speaking sessions are planned including a final day panel discussion in addition to a poster session. Some 20 scientists are to present their research on butadiene, isoprene, chloroprene, ethylene and propylene research work. www.iisrp.com/symposium

90

FEBRUARY / MARCH 2014

EVENTS Saudi PPPP

17-20 February

Riyadh, Saudi Arabia

www.saudipp.com

Propak Packaging Innovations Conf

18-19 February

Sandton

www.specialised.com

Pipeline Coating

24-26 February

Vienna, Austria

www.amiplastics.com

PVC Formulation

24-26 February

Düsseldorf, Germany

www.amiplastics.com

Sino Pack / Inno Pack

3-5 March

Guangzhou, China

www.chinasinopack.com

Tyrexpo Africa

4-6 March

Sandton Convention Centre, Jhb

www.eci-international.com

Label Summit Africa

10-11 March

Cape Town Int’l Convention Centre

www.labelexpo.com

World Pultrusion Conference

6-7 March

Lisbon, Portugal

www.pultruders.com

JEC Europe

11-13 March

Porte de Versailles, Paris

www.JECcomposites.com

Drinktec Africa

18-19 March

Gallagher Convention Centre

www.fdt-africa.com

Multilayer Films Asia

24-26 March

Bangkok, Thailand

www.amiplastics.com/events

Propak East Africa

1-3 April

Kenyatta Int’l Conference Centre, Nairobi

www.propakeastafrica.com

Stretch & Shrink Film

1-3 April

Maritim Hotel, Cologne, Germany

www.amiplastics.com

European Thermoforming Conference

3-4 April

Prague, Czech Rep

www.e-t-d.org

ArabiaMold / Plastvision Arabia

7-10 April

Sharjah, UAE

www.arabiamold.com

Tube & Wire Trade Fair

7-11 April

Dusseldorf, Germany

www.tube.de

Polymers in Photovoltaics 2014

8-10 April

Maritim Hotel, Cologne, Germany

www.amiplastics.com/events

Chinaplas

23-26 April

Shanghai New International Expo Centre

www.ChinaplasOnline.com

Plastic Closure Innovations

28-30 April

Berlin, Germany

www.amiplastics.com

Interpack

8-14 May

Düsseldorf, Germany

www.interpack.com

CeMAT

19-23 May

Hannover, Germany

www.CeMAT.com

AfriMold

3-4 June

Sandton Convention Centre, Johannesburg

www.afrimold.co.za

UTECH North America Conference

4-5 June

Charlotte Convention Centre, North Carolina

www.utech-north-america.com

PPS30

8-12 June

Cleveland, Ohio, USA

www.pps30.com

FIP Solution Plastique

17-20 June

Lyon Eurexpo, France

mlanteri@idice.mc

Drink Tech Africa

22-24 June

Gallagher Estate, Midrand

www.biztradeshows.com

Celebrating 50 years of rubber production in South Africa As we celebrate our golden anniversary, we remain committed to being a leading and innovative rubber company. We will continually strive to achieve customer service excellence and we thank you for sharing in our success. www.karbochem.co.za SALES AND MARKETING

Eastgate Office Park, Ground Floor, Block A South Boulevard, Bruma 2026, South Africa

T +27 (0)11 601 1660 F +27 (0)11 616 6651 E kbcinfo@karbochem.co.za

CLASSIFIED ADVERTS Advertisers: February / March 2014 Ampacet Carst & Walker DemaPlastech DH Polymers Frontier Industries Fukutomi Gamma Meccanica Haitian Huayuan Hosaf Intrinsys Jenowill Karbochem LeadershipWorks Masterbatch SA MBT MGMW Trading Miracle Mould MJH Machine Tools Mould Base SA Orion Engineered Carbons Performance Colour Systems Plastamid PlastiChem Plasti-Weld Plastomark Polysaf Progetto Intâ&#x20AC;&#x2122;l Propak 2014 Protea Polymers Rawmac Relloy SABIC South Africa Safrique International SAPY Colours Sasol Polymers Seecor SES Sun Ace Sysmetric Ultra Polymers Victor Fortune Welltec Xyris Technology

01 85 33,72 43 10 42 45 80 79 29 03 90 75 65 56 50 36,37 23 55 11 53 48 IFC 73 59 71 30 88 IBC 31 89 15 26 61 OBC 13 67 17,19 27 05 62 38 39

PLASTIC WANTED TOP PRICES PAID COD PP Black â&#x20AC;&#x201C; regrind/palletised PP Colour â&#x20AC;&#x201C; regrind/palletised

Buzz Trading Hundred and Four cc Contact: Dewald Nel 083 258 3213 Work: 011 873 8050 Fax: 011 873 9145 Email: buzz104@telkomsa.net

SUBSCRIBE TO SA PLASTICS, COMPOSITES & RUBBER SA Plastics, Composites & Rubber is published six times a year and is available to people involved in the plastics and polymer industry in South Africa on a subscription basis at a cost of R285 a year. It is available in other countries in Southern Africa at a subscription cost of ZAR500 per year. International subscription, supplied by airmail, is ZAR700.

If youâ&#x20AC;&#x2122;d like to subscribe, email your details to saplastics@iafrica.com or visit our website at www.saplastics.co.za

FOR SALE Bag making machine for sale Double lane carry bag machine selling price R150 000 Also for sale 2 x bag blowing extruders 11Kw, 25 to 30kg/hr, max folding width 600mm 28:1 LD screw, 45mm dia, R75 000 Equipment as good as new Price includes VAT and delivery to DBN, GAUTG, CTWN, BFTN Looking for: Recycling extruder, good condition with force feeder 100 to 130kg/hr unit.

Must have primary and secondary feed barrels.

Have materials for sale: 99* ' Â&#x152;Q9.' 9 ' +#) "# = + \ & 7 & # == )Â? # & )-'

+#) =#[& # Â&#x201E;X-Â&#x201E; 7 & # "# =# )& )- +#) 0Â&#x17D;.Â&#x201E; )+/!

Looking for to recycle: (Eastern Cape) Pre-consumer PP, HDPE, PA, PC, Rigid PVC, ABS, ASA, PMMA Contact: Wouter de Lange 072 705 8597 â&#x20AC;˘ wouterbagman@gmail.com â&#x20AC;˘ bagman@8tamail.com

New extruder for sale Screw L/D: 38.55/1, screw diameter 100mm 45KW Siemens motor with Siemens 440 Micromaster VSD Max speed: 50 RPM. Price: POR Contact: Steven on 072 496 8363 steven@convertacor.co.za

We Buy and Sell Plastic Pallets 083 756 6897 www.premierpallets.co.za COMPOUNDING CAPACITY AVAILABLE We can compound mineral powders into PP or PE Please call Alon on 021 521 2400

THERMOFORMING TECHNOLOGY SAVE 90% of your electricity use with GN! GN (Canada): machines for reduced waste and reduced energy; Thermoforming Moulds for GN and other thermoformers EXTRUSION TECHNOLOGY FROM AGRIPAK OF ITALY Mono & multi-layer extrusion lines for the production of: ¢

? @ Â&#x2122;

Q§ Multilayer sheet for packaging; Semi-foamed sheet for thermoforming MATERIALS FOR THERMOFORMED PACKAGING

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$ #

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FOR SALE 850Kgs Virgin Hytrel 7248 Price â&#x20AC;&#x201C; open to any reasonable offer.

New price in excess of R100 per kg

Reinette Jordan Email: reinette@jcl.co.za

Contact: Dave on 083 225 8277

% ( + advert please Fax: 086 519 6089 or Tel: 021 712 1408 or E-mail: saplastics@iafrica.com www.saplastics.co.za FEBRUARY / MARCH 2014 91

SPORTS

EPDM â&#x20AC;&#x2DC;wingsâ&#x20AC;&#x2122; for joggers Lanxess rubber has excellent dynamic qualities

Fritzschis, air-cushioned shockabsorbing inserts for running shoes, made from the high-performance EPDM synthetic rubber Keltan from Lanxess, can make walking and running much more enjoyable

JOGGING is a wonderful sport â&#x20AC;Ś which can, unfortunately, put strain on joints and tendons. Now German inventor Helmut Fritzsche may have found a way to prevent these side-effects.

Through his online store (http://www. hf-sport-extra.de/) he supplies air-cushioned shock-absorbing inserts for running shoes that are intended to provide effective protection against certain orthopedic problems. The â&#x20AC;&#x2DC;Fritzschisâ&#x20AC;&#x2122; are made from the high-performance ethylene-propylene-diene (EPDM) synthetic rubber Keltan 9565Q from specialty chemicals company Lanxess. The special feature of this rubber raw material is that it can hold its own against the previously unbeatable dynamic qualities of natural rubber, while its saturated molecular structure makes it far superior in terms of aging resistance. As a result, Fritzschis can be used day in, day out.

Thanks to their unique design and the high-performance rubber grade Keltan 9565Q with its optimized dynamic qualities, Fritzschis can reduce stress peaks and make walking and running much more enjoyable.

â&#x20AC;&#x153;The reason for the exceptional dynamic qualities of Keltan 9565Q is the particularly high molecular weight of our highperformance EPDM rubber,â&#x20AC;? said Dr Niels van der Aar of Lanxessâ&#x20AC;&#x2122; Keltan Elastomers business unit in Geleen, the Netherlands. â&#x20AC;&#x153;Put simply, this is because the long molecules interlink extremely effectively, which gives the polymer network a very high load-bearing capacity. Forces that are introduced are stored and, compared to other rubbers, less energy is converted into heat, which means that the vulcanizates react with exceptional elasticity. In this way, our Keltan 9565Q is as dynamic as natural rubber, but is way ahead in terms of aging resistance.â&#x20AC;?

The latter has always been the Achilles heel of natural rubber. Air, heat and humidity â&#x20AC;&#x201C; unavoidable in running shoes â&#x20AC;&#x201C; can cause this natural material to become brittle over

< & ¤

$

< www.lanxess.com

â&#x20AC;&#x2DC;Extreme recyclingâ&#x20AC;&#x2122; Over 100,000 recycled plastic bottles played a prominent role in the ESPN X Games in Aspen, Colorado, USA, during

"

into course signage and lanyards for the winter extreme sports competition.

Repreve also created merchandise such as shirts and beanies from the recycled material. To highlight the use of recycled plastic, the company distributed thousands of lime green Repreve beanies

#$ % campaign to focus attention on recycling "

www.repreve.com 92 FEBRUARY/ MARCH 2014

The Protea Polymers Team offers innovative solutions to the plastics industry with the backing of world class products and industry professionals.

Touching lives everyday

â&#x20AC;&#x153;more than just a chemical supplierâ&#x20AC;?

Johannesburg: +27 (0) 11 842 3600 Durban: +27 (0) 31 450 5777 Port Elizabeth: +27 (0) 41 401 5500 Cape Town: +27 (0) 21 550 8232 www.proteachemicals.co.za

Fax: +27 (0) 11 842-3700