S a plastics '014 08 for web

www.saplastics.co.za

VOL 12 NR 4 AUGUST / SEPTEMBER 2014

CONSUPAQ REAPS REWARDS OF SPENDING

Performance expands white, extender masterbatch range

Leading the way –

ARMSA ROTATION 2014 SHOW DRAWS INT’L AUDIENCE

Prominent women in SA plastics industry ATES SRF INAUGUTERD TICA HUGE, SOPHIS ANT BOPP FILM PL

Compete against imports – exploit DESIGN

‘Bonus time’ at Finke Plastics

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

Lumotech diversifies with nonautomotive lights

Off-grid house from Rhino Plastics 8

Sync Tooling repairs moulds 22

33

Durethan® and Pocan® EF (Easy Flow) and XF (Xtreme Flow) Grades

Give you a reach that stretches far beyond other materials.

longer flow paths | efficient energy usage • Flow paths become longer than ever imagined, while the product properties remain virtually unchanged.

• Option of reducing wall thickness with the improved flow properties.

• Cycle times can almost be cut by 15% to 30% increasing output and saving time and energy.

• Use of smaller machines which use less energy.

• Larger processing window in terms of temperature and mould filling pressure.

• Significantly enhanced stiffness and strength.

Durethan® and Pocan® are registered trademarks of LANXESS

September

is clean-up sa month

20 14

BY THE WAY ...

Publisher: Martin Wells (martin@summitpub.co.za) Editor: Tessa O’Hara (tessa@summitpub.co.za) Editorial assistant: Heather Peplow (heather@summitpub.co.za) Financial manager: Lisa Mulligan (lisa@summitpub.co.za) Designer: Jeanette Erasmus Graphic Design (jeanette.erasmus@lateraldynamics.co.za) Bronwen Moys Blinc Design (bronwen.clarke@gmail.com)

A solar-powered plane featuring PU components for lightweighting made its inaugural flight in June. The Solar Impulse 2 is set to undertake the world’s first fuel-free circumnavigation of the globe and is a larger, upgraded version of one that flew across America last year.

The sun-powered craft flew from Switzerland’s Payerne airfield on 2 June and returned two hours later.

The craft was invented by Bertrand Piccard and Andre Borschberg using, as previously reported, PU products from Bayer MaterialScience to reduce its weight. Its cockpit features Bayer’s lightweight foam insulation system Baytherm Microcell as well as adhesives and coatings from Bayer. The carbon-fibre aircraft has a 72m wingspan — wider than a Boeing 747 jet — yet weighs just 2.3tons.

Astrapak future: Opinions differ 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@summitpub.co.za Printed by: Tandym Print, Maitland, Cape Town SA Plastics Composites + Rubber Technology is published six times a year and focuses on these industries in South and southern Africa. We welcome news, articles, technical reports, information in general and photographs about events and developments related to the plastics industry.

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

Copyright: All rights reserved.

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

Plastics Institute

Association of Rotational Moulders of South Africa

of Southern Africa

Plastics Converters Association

PET Plastic Recycling

Plastics Federation

South Africa

of SA

Institute of Materials

THE article in our last issue on the recovery process underway at Astrapak generated various opinions about the potential for success.

One supplier suggested the group simply did not have sufficient people to make it through: by ‘people,’ he meant capable managers.

We, as neutral observers of the industry, had suggested several years ago that Astrapak needed at least a dozen high level managers who would be able take over running of the various group converting operations. The kind of person who you could say to: ‘Go and run that extrusion business in Durban and make it profitable ASAP’.

Businesses can be turned around with effective management, no doubt, and this is not far-fetched in the Astrapak case, since ALL the group operations were very well run … formerly. The companies purchased by Astrapak over the approximate decade while the group ran positively were correctly identified as being profitable and successful.

But the problem since is two-fold: when the former ownermanagers left (and most of them did after serving out management contracts), a gradual slide started in virtually all cases; and secondly, the type of people needed to run such operations simply don’t exist.

Such highly capable and motivated individuals are either running their own businesses or are already involved with one of the bigger groups. Here and there you will find individuals who are capable of such achievements, but they are extremely hard to find.

Surprising scenario after fire at films supplier A FIRE at a Johannesburg films supplier’s warehouse in June stopped the business dead in its tracks … only for it to be bailed out by a customer and a rival (yes, that’s correct).

The business has been supplying films from the Far East for several years and – from what we’ve heard – the quality, reliability of supply and prices are hard to beat. At the end of the day, that’s what customers pay for (and there’s nothing to stop South African film producers from competing in foreign markets on the same basis).

But a crisis was averted when a rival agreed to step in and supply product, and a customer offered two vehicles to assist with deliveries ... without which the firm would very possibly have been cooked.

Good fortune was at hand too, when a delayed container arrived just days after the conflagration.

Shock after a fire can result in victims under-estimating the hazards of the recovery process, or panicking completely, whereas a helping hand at that moment can go a long way towards calming the process. Thanks are due to the good METHING HAVE SO … IF YOU Samaritans of this scenario. It never you TO SAY ht side: if pays to kick a man when he’s down. at the brig m to Look wisdo e gem of at have som rite to us w se ea impart, pl ica.com fr ia s@ saplastic

VOLUME 12 NR 4

AUGUST / SEPTEMBER 2014

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

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

INDUSTRY NEWS SRF inaugurates sophisticated BOPP ďŹ lm plant Consupaq is reaping the rewards of spending If import-parity is not the price setting model, what is?

10 recycling projects to receive POLYCO funding support West African is new supplier for BOPP ďŹ lms manufacturer Taghleef Leading the way – Prominent women in South Africa’s plastics industry SA pangolin seized in Chinese scrap plastic import

8

18

53

24

32

59 34 44 46

62

47 48 50

54

68

56 58

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s 3IMULTANEOUS READOUT OF TEMPERATURE set-point and actual value s #LEAR ARRANGEMENT OF OPERATING AND indicating elements s 3OLID STATE RELAY 332 INSTEAD OF heating contactor

WORLD NEWS Sealing the deal for Hong Kong-Zhuhai-Macau Bridge PVC recycling on the rise in Europe

UĂŠ ÂœÂ˜ĂŒĂ€ÂœÂ?Â?iÀÊ,/ĂˆÂŁĂŠ*

UĂŠ i>ĂŒÂˆÂ˜}ĂŠV>ÂŤ>VÂˆĂŒĂžĂŠÂ™ĂŠÂŽ7 UĂŠ œœÂ?ˆ˜}ĂŠV>ÂŤ>VÂˆĂŒĂžĂŠĂ“{‡™äʎ7 UĂŠ*ՓÊV>ÂŤ>VÂˆĂŒĂžĂŠĂˆĂ¤ĂŠÂ?ÂˆĂŒĂ€iĂƒĂ‰Â“ÂˆÂ˜]ÊΰnĂŠL>Ă€

Type 150 Smart

26

DESIGN Street Shark nabs JEC Americas Innovation Award JEC Europe 2014: Champions of composites innovations Compete against imports – exploit design

Temperature control units for water up to 90°C

12

ASSOCIATION NEWS ARMSA: Rotation 2014 draws delegates from around roto world PLASTICS│SA: Local plastics industry commits to ‘Zero Plastics to LandďŹ ll by 2030’ IOMÂł: Montech’s rubber process analyzer has wide capabilities SAPPMA VIII in September PISA: Golf days around the country SAVA: Vinyl SA 2014 Conference

Type 90 Smart

6

82 87

71

s !LL COMPONENTS EXPOSED TO WATER ARE made of non-rusting materials, hence long service-life s !CHIEVES ESTIMATED REDUCTION IN REJECTS AND INCREASE IN PRODUCTIVITY

ON THE COVER Rototek of Newark, England, is a leader in the area of three-layer rotational moulding – that’s two skin layers with foam core technology, which is increasingly becoming an area for value-add for rotational moulding manufacturers in South Africa.

Martin Spencer of Rototek was the keynote speaker at the recent ARMSA Rotation 2014 conference, during which he gave a number of presentations where he discussed solutions for technical challenges in this area. The ‘Glink’ basins are roto moulded for a well-known design brand in the United Kingdom, offering several advantages, including the ability to colour readily. – Read more on page 35. www.rototek.com

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THIS ISSUE Design to fight imports Mike Wythe of the Tshwane University of Technology’s 3-Dimensional Design unit is keeping his finger firmly on the design button!

In his column this issue Mike says exploiting design is one way to compete against imports.

– See pages 58-9 Lamellae fruit bowl from Snapp Design – www.snappdesign.com

Women are buoying our industry

Martin Wells

, Publisher

Sector association appointments not just window dressing ITH August 9 being National Women’s Day, it’s appropriate that we – for the first time – pay tribute to the women who are buoying our industry!

COMMENT

W

The various sector associations which have emerged in the industry over the past decade-plus a few years have in most cases opted for female managers. But it wasn’t simply a case of appointing women to brighten things up a bit: these people have had to be smart to deal with wide-ranging challenges.

The women who have been tasked with managing PETCO, POLYCO, PSPC; SAPPMA, SAPRO and SAVA (as well as the rebranding of the umbrella body Plastics|SA) have had to take responsibility for the full representation of their various materials’ public image as well as other tasks. We’re grateful for what they’re doing, and stylishly too. Read about the roles the various ladies play on page 26-30.

No winners from strike There won’t be any winners from the recent metalworkers strike but, from our perspective, there will be one guaranteed result, and that unfortunately is that more workers will lose their jobs. That was the direct outcome of the 2011 edition of the labour protest – several thousand lost their jobs then. And now we’re seeing a repeat of that. So we have a badly polarised position what is proving difficult to change.

Import-parity situation Some in the industry are unfortunately celebrating the somewhat poetically set R543-million fine that the Competition Commission hit Sasol with for anti-competitive behaviour in sales of polypropylene.

Our research revealed a very different and complex

picture, however. Until a few years ago, both the local polyolefins manufacturers, Safripol and Sasol, had import protection for HD, LD and PP. It was during this era that an aggressive anti-Sasol attitude developed in the industry and even awareness of the fact that import duties were a standard feature in many countries around the world, covering many varied products, did not deter these individuals.

Since the phasing out of duties in 2010, however, the There won’t be polymer importers have not any winners been able to compete with Safrom the strike sol’s prices, and their best opportunities to sell have come when Sasol or Safripol have had production problems and not been able to supply. See on pages 12-13.

Plastic scrap exports are dodgy The fact that local recyclers cannot compete with Chinese buyers when it comes to purchasing plastic scrap should raise alarm bells. Why? Simple arithmetic actually: the present value of collected plastic material ranges from R2500-4000 a ton, but the ton of collected pangolin scales intercepted in a shipment of PET scrap (ex-SA) by customs officials in Hong Kong recently had an estimated value of R5-million. The latter figure may be inflated, but would vastly exceed the value of the entire container of scrap of about R70,000. In 2011 a shipment containing a large number of rhino horns was intercepted too, not surprisingly also hidden in bales of PET containers. We appreciate the diligence of the Hong Kong officials, using x-ray detecting devices. – See our story on this unsavoury situation on page 32.

‘Rock 1’ kayak from Rototek of the UK; Fondue Slippers from Tokyo designer Satsuki Ohata are created by dipping a foot mould in liquid PVC; automotive suspension springs made of glass fibre-reinforced polymer for Audi AG (about 40% lighter than the steel alternative); China’s growing rail industry is making major use of Makrolon polycarbonate from Bayer; Hydrafiner cosmetic range from Consupaq of Durban; Polyplastic and Owens Corning developed a new grade of glassfibre-reinforced PP for use in washing machine tubs

SRF inaugurates huge, sophisticated BOPP ďŹ lm plant Perfect base for SRF group to implement its African growth strategy SRF Flexipack has commissioned its state of the art BOPP ďŹ lm manufacturing line in Cato Ridge, KZN, a US$65-million investment which constitutes one of the biggest ever ventures in the South African plastic converting market.

The ultra-modern plant is the ďŹ rst BOPP manufacturing site built outside of India by SRF Flexipak, which is part of SRF Group (formerly Shri Ram Fibres), one of India’s largest and oldest chemical and industrial dynasties.

The 18-month construction project was completed in November. Phase one of SRF’s long-term strategy is to install up to four ďŹ lm lines on the site.

The ergonomically-sound factory includes a new ďŹ ve-layer coextrusion plant and an imposing 150m-long and 8.7m-wide BrĂźckner BOPP ďŹ lm line, complemented by a top-of-the-range 2.8m Applied Materials metalliser, a Kampf rewinding and slitting hall and a worldclass warehouse terminal. Also on site is a central service building, an administration building and canteen – all sized to cater for

the proposed expansion to four lines.

Manufacturing operations are carried out by a 160-strong workforce, supported by highly-experienced management and sales teams. “As African economies grow, and as transport and distribution infrastructures improve, more and more multinational brand owners are recognising the potential for packaged food production in Africa. In turn, they’re asking packaging convertors to deliver sophisticated exible packaging solutions that offer excellent barrier properties for extended shelf life and are easy to transport,â€? said Grant Page, SRF Flexipak’s country head.

With its ďŹ rst-world infrastructure and stable economy, South Africa is the perfect base for SRF to implement its African growth strategy. Local BOPP ďŹ lm demand stands at 31,000 tons/annum. “This line has the capacity to extrude 80 tons/day, providing local and export markets with consistent quality, high-clarity ďŹ lm, produced using the world’s foremost equipment and processes,â€? said Page.

Production commenced in late November and has run smoothly since day one.

Members of the SRF team at the commissioning of the huge line in Cato Ridge earlier this year

“From the very ďŹ rst mill roll, the 8.7m-wide line has been producing highquality ďŹ ve-layer plain and coextruded ďŹ lms between 15 and 40 microns – in line with local convertor demand,â€? he added.

Flexibility, stability, speed and superior ďŹ lm quality Combining the process know-how of SRF and BrĂźckner, the BOPP line incorporates a ‘direct uff’ recycling system and BrĂźckner’s well-proven TDO heat recovery technology, which allows for considerable energy savings. “Every aspect of the fully-automated

New SRF plant – no longer need to resort to exports!

We talk to Grant Page, Country Head of SRF Flexipack, about the group’s new venture in Africa SA Plastics: Why has SRF group invested in South Africa and why is the plant situated in Cato Ridge?

Grant: For several reasons: ďŹ rstly, there’s a gap in local BOPP market, which, until now, has largely relied on imports. However, we have a very good supply chain here; Sasol and Safripol are producing in excess of three hundred kilo tons of polypropylene per annum; and there’s a growing need for the ďŹ lm. Secondly, SRF are experienced in doing business locally as we already have a technical textiles business in PE, so we haven’t jumped into the ‘unknown’. The decision was to base the factory in KwaZulu Natal as almost 55% of our customers are based in Durban.

Also, the EThekwini Municipality has earmarked Cato Ridge to be a dry port. Containers will be 6

AUGUST / SEPTEMBER 2014

railed and stored here to reduce congestion at the port. There’s lots of land available in the area, as well as a constant supply of electricity.

SA Plastics: SRF Flexipack has entered into a regional market where there is already one

manufacturers also constitutes a chuck of

I’m more than conďŹ dent that we’ve made the right move. We have invested in the best-of-breed with the Bruckner line, as well as created a plant designed for efďŹ ciencies. The local operation is managed according to the successful Indian model. So, with Indian expertise, this region’s great infrastructure and local young talented staff,

we have a winning formula. In fact, right now, we have a signiďŹ cant share of the market. We’re also currently working toward our ISO certiďŹ cation, which will put us out on top.

SA Plastics: I: Is the intention to supply the

! "

your view is the potential for sales of these

" # Africa has deďŹ nitely been part of the logic in building the plant here. We have an existing customer base into Africa from our Indian plants, we are currently focusing on the SA market but will expand our reach shortly SA Plastics: Besides standard packaging

$

#

used in the signage markets?

INDUSTRY NEWS

The massive 5 layer Bruckner machine, which includes 2.8m metaliser, giving the option to produce clear, metallised and white ďŹ lms, is situated in a 150m-long hall, making it one of the largest plants in the industry in South Africa

process is designed to maximise up-time, yield and raw material efďŹ ciency. This ensures exibility, production stability, fast product changes and, ultimately, superior ďŹ lm quality,’’ said Page.

Other plant design highlights include water run-off to a holding dam, air conditioning along speciďŹ c sections of the line, a production process with 100% reusable internal waste and a pallet recycling programme. Overseeing production quality is a professionally-staffed laboratory, featuring cutting-edge testing facilities.

Ludwig Eckart, COO of BrĂźckner Maschinenbau, supplier of the BOPP extrusion line, said “The African packaging industry is developing very positively, partly with two-digit growth rates. With a modern infrastructure and stable economy, South Africa is the perfect base for SRF to implement its African www.srf.com growth strategy.â€?

We currently supply two primary markets: the packaging market with a heat sealable range between 15-40 microns, and the tape and textile market with product that’s not heat sealable. The bulk of our demand is for these products and hence our current focus. However, our line has the capability to produce 12–80 microns and we have recent experience with Bio ďŹ lms in India therefore we can expand into these areas as the demand materializes. The site has been built to accommodate four lines in various permutations between BOPP and polyester and we’ll eventually look at further investment, but right now we need to bed down with what we have.

SA Plastics: %

industrial group: does SRF Flexipack enjoy & $ $

$ advantages from SRF’s international activities?

Absolutely! The New Delhi-based company is quite diverse, supplying four core markets, ranging from chemicals to textiles. The synergy

comes in from the packaging ďŹ lms division, which essentially processes BOPP and BOPET. The reason we ramped up so quickly was because of the collaboration we have with the group. The company’s total quality management philosophy is driven across the group, which, obviously, includes us.

SA Plastics: '

& & & have extensive manufacturing experience from & & ( # ) $ #

& ( # * $ &

# $ $

are the particular strengths of the team you’ve

+ $ Life has ways of going in circles – my experience with Nampak has perfectly moulded me as the team leader for a BOPP ďŹ lm manufacturer, and the ďŹ rm relationships I made with colleagues and clients back then are paying dividends now. Essentially, we’re a commodity supplier, but our unique selling point is that we can accommodate even small customisations for local converters so they don’t

have to resort to imports. The team we have assembled in Cato Ridge is a mixture of SA youth and Indian BOPP experience this has generated a unique culture of energy and enthusiasm I have no doubt this team will deliver excellence.

The launch of SRF Flexipack is a positive story for South Africa. The business model has proven to be sound; we are now manufacturing $60 million worth of product that was previously imported; we’ve invested $65 million in equipment; and we’ve created employment, including 160 direct jobs going forward and at least 200 indirect ones through contractors. It was an easy decision for me to become part of this exciting venture. “This line has the capacity to extrude 80 tons/day, providing local and export markets with consistent quality, high-clarity ďŹ lm, produced using the world’s foremost equipment and processes,â€? says Grant Page, SRF Flexipak’s country head AUGUST / SEPTEMBER 2014 7

INDUSTRY NEWS

Consupaq is reaping the rewards of spending New hybrid tube printer, new bi-injection moulding technology, new multi-layer extrusion blow moulding machine, ISO accreditation CONSUPAQ, a division of the Astrapak Group, is reaping the benefits of several recent investments.

Celebrating a decade of producing tubes this year, the company has become a leading manufacturer of plastic extruded tubes for the South African cosmetics market.

8

AUGUST / SEPTEMBER 2014

Aligned with Astrapak’s major restructuring programme to cement the Group’s position as the packaging manufacturer of choice, Consupaq’s recent capital spending has hugely extended its capabilities. The company produces a range of extruded tubes of various sizes for different applications; thin-wall jars, thick-wall, glass lookalike cosmetic jars; and custom products for the high end cosmetic, personal care and medical sectors. Its portfolio of clients includes most of the major brands in the personal care sector.

Late last year it acquired a new hybrid tube printer capable of combining screenprinting with flexographic printing technique applied directly on to tubes, a first in Africa. This allows Consupaq to offer the market the best of both printing technologies – high definition image printing combined with bold screen printing of text.

This is particularly imperative, explains Consupaq general manager Robin Rigney, in order to keep their customers abreast with international trends. Besides that, it’s what today’s customer wants. “The demand for high definition graphics and the ability to print life-like images on tubes is growing. These printing techniques have great potential to increase the perceived value of tubes, which is a great marketing tool for brands and manufacturers,” says Rigney. “We have been able to take the tube market to a whole new level with this technology.

“The positives coming out of Astrapak’s restructuring are growing from strength to strength, and we are benefitting from the capital investment they’re putting in to achieve that,” he comments. Two years ago, the company invested in bi-injection moulding technology; again, a first in Africa for the personal care market that resulted in an import substitution for one of its major clients.

“Through this investment we brought new innovation into the sector, as well as providing an import substitution; both

Consupaq has been a constant Gold Pack Award winner since 2005, with products such as the Lucid range for cosmetic house, Annique

hugely beneficial,” says Rigney. The bi-injection technology allows Consupaq to mould two different materials or two different coloured materials simultaneously.

A third major investment was the acquisition of a multi-layer extrusion blow moulding machine that has opened up new avenues for ideas, innovation and markets.

“In addition to these investments, we are certified compliant with ISO 22000 and PAS 223,” says Rigney. “Although we focus on the personal care and household segment, we went for the top end food safety accreditation to benefit our clients and explore new markets. It underpins our commitment to provide leading edge innovation to meet the most discerning requirements of the

Totally ‘off-grid’ house from Rhino Plastics WHAT started as a venture making refuse bags from recycled material in Dimbaza in the 1980s and gradually evolved into the production of sophisticated agricultural films finally flowered for Rhino Plastics recently when it put it all together in the development of a fully sustainable, offgrid house concept.

‘House Rhino’ at the Crossways Farm Village near Port Elizabeth is testament

to Rhino Plastics MD Brian van Niekerk’s ceaseless search for sustainable and environmentally-friendly construction solutions.

The pioneering ‘green’ house is not just off-grid from an electrical perspective: it is self-sufficient in terms of its water and effluent requirements too, using the latest technologies, materials and capabilities.

The latter is really the key aspect in the

project: Van Niekerk has applied his mind to every aspect of the development.

Main features include: roof-mounted solar photo-voltaic with a bank of zero-maintenance batteries charged by two inverters, giving the house autonomy; water sustainability achieved through rainwater harvesting (with 30,000 litres of storage tanks);

The house at Crossways Farm Village near Jeffrey’s Bay includes 1) photo-voltaic (PV) system; 2) invertor/MPPT/Battery for PV system; 3) solar geyser; 4) flat plate solar panel for hot water; 5) heat pump for geyser hot water; 6) heat pump for under floor; 7) heat pump for under floor cooling and swimming pool heating; 8) heat storage tank for under floor heating and cooling; 9) indirect S-solar panels for under floor heating and cooling; 10) bio-gas digester; 11) bio-rock effluent treatment plant; 12) sump; 13) tank and ozone treatment; 14) rain tank with ozone treatment; 15) under floor heating and cooling; 16) methane gas to stove and fire place;) 17) water & energy/ saving showerheads; 18) LED lights; 19) double-glazed doors & windows; 20) polycarb roofing; 21) polycarb skylights; 22) roof garden; 23) chimney for passive cooling; 24) irrigation system; 25) aqua garden system; 26) dampseal plastic water proofing membrane; 27) enviro-Tuff roofing insulation; 28) bulk ceiling insulation; 29) invertor DC pool pump; 30) ozone pool sterilization

JUST BRIEFLY

CompositesSA created

Consupaq’s new hybrid tube printer is capable of combining screenprinting with flexographic printing technique applied directly on to tubes, a first in Africa

markets that we serve.”

Consupaq’s journey began in 1997 and has grown to become a major packaging supplier to the local personal care and cosmetic market. In 2005, Astrapak became a 60% partner; it purchased the balance of the shares three years later. Today, the company follows a lean manufacturing principle, is housed in a 8000m² facility in Durban, has a sales office in Johannesburg and a staff complement of over 150.

Its in-house design facility keeps a keen eye on global design trends to ensure a consistent pipeline to innovation and maintain its competitive edge with

international markets. It is so successful that Consupaq has been a constant Gold Pack Award winner since 2005.

“After this current round of investments, we have significantly increased the value of our asset base,” says Rigney, who reveals that more capital spending will be made later this year. Watch this space. www.consupaq.co.za

Plastomark represents Styron; West African sells Styron PS materials

“The positives coming out of Astrakpak’s restructuring are growing from strength to strength, and we are benefitting from the capital investment they’re putting in to achieve that,” says Consupaq’s general manager, Robin Rigney

construction with Aruba bricks, which offer better insulation; and the use of numerous recycled materials, such as WPC decking.

Rhino Plastics itself provided most of the plastic pipe and film (some of it produced from recycled material) while its subsidiaries Rhino Energy Solutions provided the PV panels and infrastructure; Rhino Water provided

AN association for the composites industry, CompositesSA, was established on 21 July 2014 at the offices of the Department of Trade and Industry in Pretoria in a meeting attended by stakeholders from industry and government.

CompositesSA’s interim committee is aiming to: develop a constitution, organisational model, list of members and financial model; organize the industry into sector specific composite forums; provide industry input to the DTI’s Composites Strategy and the 10-year ‘Composites Roadmap’; assist industry with accessing DTI incentives.

Dr Kjelt van Rijswijk was elected as the interimCEO; Tim van der Steene (Tag Yachts) will chair the Marine and Wind Energy Composites Forum; Shenton Botes (NCS Resins) will chair the suppliers forum, and a chairman for the Aerospace & Defense Composites Forum is to be elected at the first forum meeting.

“This is a big step for our industry as we now have established a mechanism to formally and officially provide industry input to our Government’s composite strategy,” said Van Rijswijk. “Looking forward to taking the next steps, big and small, to grow the South African composites industry.”

the water harvesting system (including the sourcing of the roto moulded tanks); Rhino Greenbuilding coordinated the architectural design; Rhino Lighting supplied the LED solutions; Rhino AgriVantage provided the biological nutrients; and Ecola Plastics produced several of the recycled materials used. www.rhinoplastics.co.za www.crosswaysfarmvillage.co.za ‘House Rhino’ – Brian van Niekerk of Rhino Plastics has put years of experience and knowhow to work in the development of the totally ‘off-grid’ house near Port Elizabeth. Here we see the man with the battery bank from the roof mounted photo-voltaic panels. The dwelling, seriously, is able to function fully without mains power, and even features underfloor heating for the winter months to boot

AN ARTICLE in our last issue about the Pulse™ polycarbonate/ABS blends from Styron, used for high-standard automotive interior components, incorrectly stated these materials are supplied

by West African Group. The engineering grade materials are in fact supplied by Plastomark.

This is a result of the fact that Ravago group, which is the owner of Plastomark, is the global distributor for Styron. Ravago (headquarters in Belgium) is an international materials supply and logistics group with several contracts in place with global material manufacturers.

Styron is a global scale supplier of various engineering plastics and emulsion polymers (latex and rubber) with revenue of a whopping $5.3-billion in 2013. The business was part of Dow group until 2010, and has practically accelerated its core activities since being ‘hived off’.

Besides the PC/ABS blends, Styron manufactures various other resins including ABS, polycarbonate, polypropylene and the Styron™ polystyrene materials. With the exception of the Styron PS materials, Plastomark is the supplier of all these materials.

West African Group is the agent for Styron’s general purpose and high-impact polystyrene materials in South Africa, and this relationship has been in play for more than a decade. www.styron.com AUGUST / SEPTEMBER 2014 9

INDUSTRY NEWS

Dr Andy Radford is involved in the development of natural fibres for commercial use, as reinforcement for composites, operating out of the well-equipped Biocomposites Centre in Summerstrand, Port Elizabeth

on natural

Researchers zone in reinforcement solutions

fibre

10

AUGUST / SEPTEMBER 2014

Biocomposites Centre looks at potential of green, sustainable plant products THE CSIR’s Biocomposites Centre of Competence is conducting research into a variety of natural fibre materials with the intention of commercializing these as sustainable alternatives for the reinforcement of composite structures.

Research has focused on agave, flax, hemp, kenaf, sisal and even pineapple and soya. Previously the fibre tended to be gathered after the harvest of the fruit or crop, but more recently, due to the greater value now attached to naturally sourced materials, the cultivation of crops for the sole purpose of fibre extraction has become a reality. This is partly due to the desire of global brands such as Mercedes Benz and Coca Cola to develop ‘green’ sustainable material alternatives.

According to Andy Radford of the CSIR Biocomposites Centre in Port

Elizabeth, the potential value of the natural fibre is far greater once its suitability for use as a composite reinforcement is proven. Several natural fibre crops have been developed as non-woven fabrics, but use as composite fibre offers a substantially better return for farmers.

A further potential advantage is that ‘no till’ farming practices are preferred, which is a significant cost saving for the farmer.

The challenge at present is to determine the right cultivars and most suitable quality of the various plants, as well as where in the country and what times of the year are most suitable for optimum cultivation. It was found for instance, with hemp, that fibre from the younger plant stalks achieved a higher tensile performance, whereas

previously it was considered that the fibre extracted after the second year growth was preferable.

The Biocomposites Centre is operating out of the former textiles development centre in Summerstrand, Port Elizabeth, which possesses of arguably the foremost textiles testing apparatus in southern Africa. Radford and his team are hence able to conduct comprehensive development tests.

It’s a challenging process, however, as farmers require tangible evidence of potential earnings before putting seed down. One such project at Winterton in KZN did not yield positive results in the first year, but there is ironically a strong possibility the project will produce very good returns down the line.

Andy Radford: ARadford@csir.co.za www.csir.co.za

In this non-wovens application, a blend of 25% hemp-25% flax was thermo compression moulded with polypropylene to create a rear door panel for a Mercedes C Class vehicle. Now the CSIR is proposing to use these and other natural fibres, chopped into various lengths, as long-fibre composites

Fibre from some unlikely sources is showing potential, in this case from pineapple stems.

The researchers have found that the fibre is most suitable a year after the actual fruit has been harvested. The Biocomposites Centre is dealing with this and other surprising findings

Fibre from plants such as kenaf, hemp, sisal, flax, cotton and agave offer different characteristics

INDUSTRY NEWS

We talk to some of SA’s top polymer suppliers ü achieving the ‘correct’ price level for the given product in its market; ü dealing with the price volatility that results from short to mediumterm supply and demand economics and long-term cyclicality which are both characteristic of these markets.

The difficulty comes in when we try to define the ‘correct’ price level. Each player in a market will have their own approach to deciding how this ‘correct’ price should be calculated. In the South African context, the import parity price has been broadly established as the price a buyer would have to pay for the material if he or she elected to source the material from an international supplier rather than purchasing it from a local manufacturer.

Import parity pricing in South Africa has become an emotionally charged topic. Historically, in some instances, the local petrochemical producers were financed, subsidised and supported with taxpayer’s money. Buyers were not permitted to import the type of materials manufactured locally without express permission from the government’s Department of Trade and Industry. If such permission was granted it was usually only done with the approval of the protected local producer. Local producers held all the power. Over and above this, import duties were applied to provide further protection for the local producers.

Given that buyers were unable to source material from anybody but the local manufacturer, it is no surprise that the market became very suspicious of the way prices were set. Local manufacturers seemed able to set their prices wherever they chose. In order to defend their often criticized but completely unassailable position, the term import parity pricing was used. The problem was, and to a certain extent still is, that the manufacturers were the ones defining and calculating the so-called import parity price. Each market had its own power-brokers controlling their own interpretation of import Is there an alternative to import-pricing for polymer, and if so, parity pricing. how would such a mechanism function?

In my opinion, polymer buyers should insist on import parity WOLFGANG RAFFALSKY (PLASTOMARK): Not to my knowlpricing. However, the import parity price used in such a situation edge, all commodities (not just polymers) are priced on a global must be calculated by an independent party in an equitable, reliable, basis. sustainable and professional way. The manufacturers in any given DICK COATES (MBT): I would argue that the price is not set in market cannot be batsman, bowler and umpire in the Far East. In our view, ‘import parity pricing’ is this game. This type of price information is availjust one of a number of inputs that is taken into ‘Import parity pricing’ able in South African rand/metric tonne terms for account by the producer when setting the price of is just one of a number each of 14 commodity polymers. The information a product. Others are ‘mark up over cost,’ ‘reward of inputs taken into is also available in indexed format to make it as on the investment made,’ ‘what the market will accessible and relevant to the smaller players, as account by the bear,’ ‘what price can you get elsewhere,’ ‘what’s it is to the bigger players. the competitor’s price’ and ‘what’s the price on producer when setting The indices are calculated relative to base pricco-produced products’. There may be others: the price of a product’ es in August 1998. This is a significant reference petrochemicals markets are complex arenas and point in commodity markets because it represents the relative contribution from any of these inputs a natural cyclical pricing low which was strongly influenced by the will vary from time to time.

Asian currency crisis at that time. This pricing information is someAt the end of the day, the producer has to reward his investment. times referred to as ‘fair value pricing’ to avoid the strong emotions If he can’t reward the investment already made, the next investment associated with the term import parity pricing. will be in something else, somewhere else, where he can make the Price smoothing techniques are also available to eliminate the reward. alarming volatility experienced by South African markets due to the MIKE REX (GLOBAL COMMODITY ANALYSTS): In my view Rand/Dollar exchange rate and fluctuating international polymer there are two important issues with commodity pricing for plastics prices. converters and their downstream markets. These are JUST about everyone in the industry, one imagines, is trying to get the best prices for the materials, products or services he or she supplies. By ‘best,’ read ‘highest’. The market, however, does not simply allow you to get what you want. Until a few years ago, both the local polyolefins manufacturers, Safripol and Sasol, had import protection for HD, LD and PP. It was during this era that an aggressive anti-Sasol attitude developed in the industry and even awareness of the fact that import duties were a standard feature in many countries around the world, covering many varied products, did not deter these individuals.

Since the phasing out of duties in 2010, however, our research suggests that the polymer importers have not been able to compete with Sasol’s prices.

The consensus in the industry is that import-parity pricing is the standard and that the given price for any globally available material on any day is the global price – specifically, the price at which the material can be landed in a country at. In South Africa, prices for commodity polyolefins are set in the Far East, specifically China, and prices for materials produced in South Africa or supplied by importers follow this cue.

But is there universal agreement in this regard?

We refer to the matter of the fine imposed on Sasol by the Competition Commission for anti-competitive behaviour, due to its pursuance of import-parity pricing.

We asked a number of South Africa’s top polymer suppliers if there are alternatives to the existing price-setting model. Here we publish the replies of the respondents: with some of the questions we supply only what in our view is the most interesting reply; in others we supply the replies of several.

12 AUGUST / SEPTEMBER 2014

In your experience, what is the standard in other countries?

COATES: It’s a global business. If you can’t make an adequate reward by producing and selling in one country, you go and produce it and sell it elsewhere.

REX: Polymer, and indeed any other commodity material, can only be sold at below substantiated import parity price on an ongoing basis if that market is subsidised by some third party. PolyDick Coates of MBT, Wolfgang Raffalsky of Plastomark and Mike Rex of Global mer producers need to reward the substantial capital they invest Commodity Analysts participated in the interviews, in which the polymer price setting in their manufacturing plants. Market cyclicality delivers alternating scenario is analysed (MBT and Plastomark are among the top suppliers of polymers in periods of profit and loss for these producers.

South Africa; GCA is an analyst of the polymer supply market and price trends) The detractors of commodity producers focus on the significant profits and ignore the considerable losses that characterize these What circumstances could justify selling at prices below the markets. If producers in a given region are required, for whatever import parity level? reason, to sell below the ruling market prices at any given time COATES: Perhaps the producer is overstocked, they will be compromising their ability to remain ‘Detractors of perhaps he wants to encourage the use of a in the business further down the track. polymer to replace a ‘traditional’ material in a certain In my opinion there are no circumstances commodity producers product? But in both these cases the sustainability which would justify selling polymer at below subfocus on the significant of the discounted price is limited by the return on his stantiated import parity prices to all, or even part profits and ignore the investment. of the South African market. If the IDC, the DTI or considerable losses RAFFALSKY: I don’t think there could be any any other third party wants to subsidise polymer that characterize these ‘justification’; ultimately such forced pricing would pricing to South African converting companies, markets’ lead to the demise of the local polymer producers then those subsidising partners would have to and then one would have to rely on international source the polymer materials at market related supplies anyway. prices and cover the cost of the subsidies themselves.

REX: Polymer, and indeed any other commodity material, can only We all know the mess that can result from poorly thought out be sold at below substantiated import parity price on an on-going basubsidies. Every market needs to be able to wash its own face in sis if that market is subsidised by some third party. Polymer producers the long run. It is pointless subsidising businesses which will inevitably close down the moment those subsidies are removed. There need to reward the substantial capital they invest in their manufacturing plants. Market cyclicality delivers alternating periods of profit and is no long-term future for polymer convertors who require ongoing loss for these producers. subsidies to justify their existence in the South African market.

AUGUST / SEPTEMBER 2014 13

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INDUSTRY NEWS

RAFFALSKY: It has been standard practise for decades that domestic prices in the various regions are higher than the corresponding export offers. One just has to consult the weekly price monitor publications (such as Platts) to see that; thus Sasol’s pricing policy is in line with its peers around the globe.

Sasol has in the past three years plus charged significantly less than they could have in terms of ‘import parity’ – in essence, their prices appear to have been a compromise between import parity and export netbacks. The low level of imports on polypropylene proves this.

The fact therefore is the opposite of what they are being ‘charged’ with – i.e. local converters are benefitting from Sasol’s pricing. Forcing Sasol into selling at export netbacks in South Africa would not only effect the economics of their operation, but essentially of the other two polymer producers as well, and essentially kill off any further investments in the long run – therefore we would have the demise of local polymer production and what would we end up with? The local converters would then have to pay full import parity, like they do on everything else, from polystyrene to ABS to PU etc.

COATES: As a generalisation, many chemicals and There appears to be the view that supplying polymer at lower polymer producers export their products at prices lower than cost would be an advantage for new converting operations: the domestic price in the country of production. This is called is there logic in that? ‘dumping’ and is quite common.

REX: There is no logic in this. None whatsoever. Lower The challenge comes when dumped product is imported into polymer prices to the market will provide established players with a country that has domestic production itself of the identical lower prices as well. New entrants will find it just as difficult to product. If the dumped product: establish themselves against existing experienced and estabü undercuts the producer in the country to which the goods are lished players. Many of our plastics converting sectors are already exported; significantly over-traded. Newer players are always going to find it ü the producer in the country to which the goods are exported, extremely difficult to get a foothold in these established markets. demonstrable harm; For any business to succeed it needs sustainable competiü and the imports of dumped product can be shown to be the tive advantages which separate it from the crowd. Raw material cause of the harm pricing cannot be a contributing factor in this scenario. As far as then World Trade Organisation (WTO) rules I know, any form of tiered pricing in a market is allow for the imposition of a counterveiling considered an uncompetitive business practice.

‘Forcing Sasol into ‘antidumping duty’ on the offending exporter.

RAFFALSKY: That view is misguided. selling at export If there are a number of exporting offenders, Polymer prices in South Africa have been driven netbacks in South then a blanket ‘antidumping duty’ may be by international prices since the mid 1980s, Africa would imposed on all product of that type originating yet plastics consumption has grown in leaps essentially kill off any in that country. and bounds (in line with the rest of the world). further investments’ Is it sustainable? Well, let’s look at a Converted products still enjoy duty protection hypothetical case of an LDPE producer who – while there is no duty on polymers; thus local makes 200ktpa and sells it at R20/kg into a domestic market converters have every chance to fend off finished goods imports. of say 175ktpa. He has to run his plant flat out so he has two Growth (from artificially low prices) could only come from exports, options of what to do with the surplus 25ktpa. These are: but potential here is, however, limited due to South Africa’s logistiü sell 25ktpa at R17/kg into the export market, finish and klaar; cal disadvantage to all three major markets. ü sell the 25ktpa at R17/kg into the domestic market, but this COATES: To a degree. But the converters themselves have to can only be done IF, by using the R2/kg discount, he can be world class to take advantage of the subsidy, otherwise you develop a new market for this tonnage and this tonnage is are asking the polymer producer to subsidise downstream inefsold ONLY into this new application. ficiency. If energy prices rose to such an extent that vinyl window frames started to become more viable, then discounting the If, as I suspect the Great South African Government would polymer price to selected converters for a limited period of time like, he is forced by legislation to sell this tonnage into his to hasten market penetration would be perfectly logical. What is probably not logical is for the producer to have to give a ‘feel good’ existing, fully subscribed market at R17/kg, then the WHOLE 175ktpa will be devalued by R3/kg … and the manufacturer still discount which merely translates to a new luxury vehicle in the has the problem of what to do with the extra 25ktpa surplus to converter’s parking lot. the domestic market requirements and the whole investment case is jeopardized.

Sasol appears to be charged with exporting polymer at You end up with the case that the Great South African lower prices (specifically into Africa and to Brazil) and hence Government sets the price in the market – and no petrochemical potentially disadvantaging local convertors: is exporting producer will invest billions of US$ under this scenario. What is of polymer at a lower rate than that achieved in a polymer really scary is that the Great South African Government is trying manufacturer’s ‘home’ market a reality in the industry interto do this RETROSPECTIVELY! nationally? And, if so, is this a sustainable strategy?

The detractors of commodity producers focus on the significant profits and ignore the considerable losses that characterize these markets. If producers in a given region are required, for whatever reason, to sell below the ruling market prices at any given time they will be compromising their ability to remain in the business further down the track.

In my opinion there are no circumstances which would justify selling polymer at below substantiated import parity prices to all, or even part of the South African market. If the IDC, the DTI or any other third party wants to subsidise polymer pricing to South African converting companies, then those subsidising partners would have to source the polymer materials at market related prices and cover the cost of the subsidies themselves.

We all know the mess that can result from poorly thought out subsidies. Every market needs to be able to wash its own face in the long run. It is pointless subsidising businesses which will inevitably close down the moment those subsidies are removed. There is no long-term future for polymer convertors who require ongoing subsidies to justify their existence in the South African market.

14 AUGUST / SEPTEMBER 2014

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to invest R10-million to address constraints in recycling

Members of the POLYCO board at the AGM in May included George Blackwood (POLYCO business support manager); Jeremy Mackintosh (chairman); Mandy Naudé (POLYCO CEO); Eddie van Os (Unilever); Robin Olbrich (Astrapak); Bronwyn Durham, Philip de Weerdt (Nampak) who was elected as vice-chairman, and Annabé Pretorius (SAPRO). Bernhard Mahl, Anton Hanekom and Neelin Naidoo (POLYCO Board members) were absent when the photograph was taken

Actively supporting energy reclamation projects to extract ‘green energy’

16

AUGUST / SEPTEMBER 2014

POLYCO’s strategy for 2014-2015 will focus on supporting the entire recycling industry value chain by growing volumes of separation, collection and sorting, recycling and end-use demand for polyolefin plastics.

POLYCO presented its strategy for growth for 2014-2015 at its AGM in Midrand recently during which POLYCO chief executive officer Mandy Naudé, said the organisation would invest R10-million over the next year to address current areas of constraint in the recycling industry and in line with the association’s project categories.

“POLYCO’s goal is simple: to create an organised and committed network of packaging converters united in their commitment to Extended Producer Responsibility by way of the voluntary industry-recycling levy. To use the funds paid by the convertor members to grow the tonnages of post-consumer packaging polyolefin plastics being recycled or diverted from landfill. In doing so, we aim to meet the targets set in the Paper and Packaging Industry Waste Management Plan, as submitted by industry to government,” Naudé explained.

Through its Project Support Business model, POLYCO will focus its attention on supporting the entire recycling industry value chain by growing volumes of separation, collection, sorting, recycling and end-use

demand for polyolefin plastics.

“We are committed to achieving the objective of sending ‘zero plastic packaging waste to landfill by 2030’ and will therefore be playing a very active role supporting the implementation of a wide variety of different projects that will help us achieve this goal,” said Naudé.

POLYCO will also be actively supporting reclamation of energy projects in order to extract ‘green energy’ from the nonrecyclable polyolefin plastics and other waste materials currently going to landfill sites.

Through waste beneficiation processes such as incineration, pyrolysis and gasification, a diversion of 440 000 tonnes of polyolefin packaging materials could be diverted from landfill by the year 2030, she explained.

Addressing areas of constraint in recycling POLYCO will be investing R10-million over the next year to address current areas of constraint in the recycling industry and in line with the association’s project categories below. “We are expecting the POLYCO 2013 funded collection projects to result in an additional 4200 te’s of polyolefin recyclate being available to South African recyclers per annum,” Naudé said.

1 Strategic Growth and Development Projects, which aim to increase the economically viable collection and recycling of post-consumer polyolefins. These projects focus on optimising the use of existing collection and recycling infrastructure and

Jeremy presented Robin Olbrich and Eddie Wallace of Astrapak with the group’s membership certificate

help to facilitate its establishment where it does not exist. They are required to deliver substantial growth in tonnes of material separated, collected, sorted and recycled (over 5000 tons p/a).

2 Supply Chain Efficiency Projects will support new or existing initiatives that contribute to the significant growth of sustainable, on-going collection and sorting of polyolefin plastics (between 1200 and 2400tpa). These projects focus on optimising the supply chain within the collection and recycling industry to maximise the growth in tonnes separated, collected, sorted and recycled, by addressing current supply chain constraints.

3 Waste Beneficiation Projects focus on supporting technology development projects that are aimed at the extraction of value from the polyolefin plastic packaging and other waste material currently going to landfill.

These include incineration and pyrolysis.

4 End-use Development/ Research and Development Projects will focus on promoting the use of polyolefin recyclate in a range of consumer product applications with the aim of replacing virgin or other materials.

5 Visible Consumer Projects initiatives do not necessarily involve significant volumes, but promote and contribute to the visible recycling of polyolefins.

The annual report can be downloaded at www.polyco.co.za

Philip de Weerdt was also elected as the new vice-chairman of POLYCO. Here Philip receives Nampak’s membership certificate

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INDUSTRY NEWS

10 recycling projects Successful applicants receive just under R4 million support funding for separation, collection and sorting projects POLYCO has selected 10 applicants to receive support funding for their projects that will have a direct impact on the growth of separation, collection and sorting of post-consumer polyolefins.

“We received 56 applications for support following our first Call for Proposals that went out on 23 March this year,” explained Mandy Naudé, CEO of POLYCO. “Each one of these submissions was carefully evaluated against the funding support criteria and a short-list of 10 applicants was recommended by the Project Evaluation Committee to the POLYCO Board for approval.”

The final step in the process saw POLYCO visiting each of the short-listed applicants at their premises, where a further in-depth review was conducted to gain additional information and to understand their businesses better.

The Project Evaluation Committee then reviewed the feedback from all 10 applicants and rated them against the agreed criteria, some of which included source of the waste, volume growth, employment opportunities created, location - waste hotspot or not, and rand per ton investment effectiveness.

The proposed funding support for each short-listed applicant was presented to

the POLYCO Board on 15 July and total funding support of just under R4 million was unanimously approved.

“We are thrilled with the final list of successful applicants who are our newest POLYCO partners. These support projects cover all the key geographical areas in South Africa and will generate an additional 16 000 tons of post-consumer polyolefin collections over the next three years, as well as create 340 potential new employment opportunities in the industry,” Naudé said.

Next steps POLYCO is interested in supporting the

The successful applicants InWaste Green Eliran Moses of InWaste: “This is a dream come true for us and we are truly honoured to be partnering with POLYCO. We see this as only the beginning of taking our business to where we want it to go.” The Moses family started their recycling operation five years ago and has grown their business. They now run a 100% vertically integrated operation, by collecting, recycling and producing products made from recycled polyolefins. With POLYCO’s funding support, InWaste Green will install new equipment in their Tembisa buyback centre and will fit cage conversions to their trucks to enable them to significantly grow post-consumer polyolefin collection and recycling volumes

Mpact Recycling Ushan Naidoo of Mpact Recycling: “We are ecstatic about being awarded POLYCO’s support funding. There is a big need for recycling projects in rural KwaZulu-Natal, and this is hopefully the first of many more to come in the region where job creation is desperately needed, and has the potential to grow polyolefin collection volumes in the area.”

Mpact Recycling has a successful and established model of buyback centres around South Africa. POLYCO will partner with them in the KZN region with the establishment of a new buyback centre www.mpact.co.za

Paul Rantofi Paul Rantofi is based in the Eastern Cape and currently services the Butterworth area. With POLYCO’s support in the form of trailers and cages, Paul will be expanding into collections from neighbouring towns to enhance polyolefin collection volumes from this previously underserviced geographic region

Verigreen “POLYCO’s funding will enable us to grow the network and reach our goal of empowering 500 ‘super mamas’. We envision that the branded trucks will be like moving billboards that helps us to spread the message of how we are empowering women and helping communities in the process,” says Thina Maziya of Verigreen, pictured here in the centre of her team of ‘super mamas’. Recently re-launched and re-branded Verigreen (previously known as Izaka Plastics), is a 100% vertically integrated collector, recycler and product manufacturer of polyolefin drawstring bags. Verigreen has launched their Super Mama project whereby they plan to empower the woman breadwinners in the family to be able to earn a living wage through the collection of polyolefin packaging. With POLYCO’s support, Verigreen will be fitting cages to their trucks to maximize the collections from their Super Mama network of collectors www.verigreen.co.za 18

AUGUST / SEPTEMBER 2014

to receive POLYCO funding support mechanical recycling of post-consumer polyolefin plastic packaging and to this end has just released its second Request for Proposals. This call for recycling support proposals covers three distinct categories: 1. Strategic growth and development projects (large-scale, new recycling projects of above 2400tpa aimed at substantially increasing the mechanical recycling volumes of postconsumer polyolefin plastics).

2. Supply chain efficiency projects (smaller projects of between 800 and 1200tpa aimed at maximizing the sustainable growth in production

volume of mechanically recycled polyolefin plastics).

3. End-use development/Consumer projects (smaller projects focused on increasing the number and visibility of products that are manufactured from recycled polyolefin polymers, with the aim of replacing virgin material and other material types).

The deadline for submissions is Friday, 29 August. Companies interested in partnering with POLYCO and apply for support funding can Mandy Naudé, CEO of POLYCO download the project criteria document and application guidelines from www.polyco.co.za

MyWaste

MyPlas Contracted Collectors

MyWaste owner, Mark Gibson: “POLYCO’s funding is a hand-up, not a handout. We have big dreams, but cannot do it on our own. Thanks to partners such as POLYCO who are willing to invest in our projects, we are able to increase traffic to our website and offer an even better service to our users.”

MyWaste has been operating for 10 years, offering a free website service for all buyback centres or recyclers in South Africa. With POLYCO’s support, the website will be further developed to become an education and consumer awareness platform on material identification, drop off locations, green product directories and green calendar events. It also offers the facility to be able to send educational messages and material requirements to the buyback centres and recyclers – to encourage collection volumes of specific material types www.mywaste.co.za

TWK Recycling George Blackwood of POLYCO congratulates Jo Kearney of TWK Recycling. Based in Grabouw in the Western Cape, TWK Recycling is a 100% BEE organisation originally formed as part of an entrepreneurial development programme. It has developed into a robust, community-supported initiative. POLYCO’s funding support will be in the form of equipment to establish three depots which will be used for collection and sorting of material in Greyton, Genadendal, Riviersonderend and Caledon. Support will also be provided for a trailer and granulator in order to service the outlying towns and reduce the logistic costs www.twkrecycling.co.za

Walter Jordaan and Johann Conradie (pictured here) of MyPlas. POLYCO will be providing equipment funding support to three contracted scrap plastic collectors in rural Limpopo, Northern Cape and Western Cape supplying to Myplas, to facilitate the collection and granulation of new sources of material for supply to their recycling operation. Myplas facilitated the applications from three of their rural collectors. The benefit of supporting contracted collectors is that there is a direct link between the growth in tons collected and the tons recycled

The Recycling Incubator (TRI) TRI has been established to implement the separation-at-source programme in conjunction with the recently commissioned Bon Accord Recycling Centre (BARC) in Pretoria. The initial phase targets 60 000 households in the surrounding feeder areas and has significant potential for the growth of separated collection volumes across all material waste streams, not only polyolefin materials. POLYCO’s funding support will be in the form of operational equipment to optimise TRI’s collection capabilities which will increase the availability of post-consumer recyclate for mechanical recyclers AUGUST / SEPTEMBER 2014

19

INDUSTRY NEWS

‘Bonus time’ at

It’s Finke Plastics New chapter for PE injection moulding business

FINKE Plastics in Port Elizabeth is under new ownership, with father-and-son team Anthony and Chris Bonus having purchased the business.

The unexpected Bonus came about quite unexpectedly: Chris Bonus, having completed his toolmaking apprenticeship, hired space from the former owner of the business, Martin Finke, in 2010 in an arrangement which suited both parties.

Finke, a German toolmaker, had wanted to retire but a previous sale of the company in 2007 had hit the rocks and he had been obligated to return to production. Having Chris as unofficial production Father-and-son team Anthony and Chris Bonus are now at the helm at Finke manager suited Finke.

Plastics in Walmer Dunes Industrial Estate, Port Elizabeth. The company Then Chris’ father, Anthony, who had been in operates a bank of Arburg injection machines, up to 180 tons clamp force, and produces a range of automotive, packaging and technical components. the automotive manufacturing sector with General Finke Plastics has ISO 9001 accreditation Motors for close to 40 years, was offered a package in 2013 and decided, well, to take it and join his son in the business. further Bonus.

Fortunately for the Bonuses, they have different but Logistics experience built up Anthony, who spent 39 years complimentary skills: Chris handles the design, toolmaking at GM, is a big asset for the company, particularly with and production tasks while Anthony runs the accounts and prioritizing orders, enabling Chris to focus on production. sales activities. Bonus snr has also, unexpectedly, found Martin Finke has meanwhile moved down the coast to himself doing deliveries lately, nipping around PE. But J Bay with his family and Dachshunds (the ‘ultimate in keeping it in the family is a good outcome for the Bonus German engineering’!), and is enjoying the more relaxed team at this stage. They are continuing with the products environment. developed by Martin Finke over the years and are planning Finke Plastics, phone 041 581 1173 to grow the business “only slightly”. The company uses cabtech@telkomsa.net conveyors on most of its machines, which is literally a AUGUST / SEPTEMBER 2014

21

INDUSTRY NEWS The new line for the production of white masterbatch and calcium carbonate filler at the Performance Colour Systems’ (PCS) factory in Meadowdale, Johannesburg, with PCS commercial manager Shaun Bouwer, Lurika van Staden, sales and marketing manager and Liaan Swanepoel, PCS production manager

Performance expands range of white and extender masterbatch World-class setup and continued investment in extruder capacity THE Performance Colour Systems boys are at it again, with continued investment in extruder capacity for the South African market.

After a two-year stint in the Western Cape, technical director, Riccardo Di Blasio has found his way back to Johannesburg and the heart of the Performance Colour Systems organisation. Riccardo’s team has purchased an innovative white masterbatch extruder to supplement existing growth, specifically for high-end white masterbatch applications and to support the ever expanding calcium carbonate business within sub-Saharan Africa.

“As more of our partners are being placed under margin pressure they are coming to us for ways of making a difference”, said Riccardo. Premium titanium dioxide pigments are used to reduce customer dose rates, and in certain non-critical applications, the need for additional use of extender

masterbatch is also growing.

“It is important that we continue to provide our customer base with relevant products, and this investment is part of that process. Our business partners have made us who we are today and listening to their feedback is critical”, he added.

Strong leadership & topnotch technical team The PCS team has grown from strength to strength and now consists of a five-man executive committee at the head of the organisation.

With the addition of Barry Shaw to the Cape Town team, technical expertise is not just a phrase thrown around within the exciting Performance Colour Systems team. Barry has a long history within the colorant and additive market and his move

to join PCS permanently and relocate to the Western Cape is testament to the drive from within to assemble the best technical team available. Barry took up his role at PCS in the first quarter of this year.

The gap in leadership in the Cape Town office caused by Riccardo’s relocation to the Johannesburg head office will be filled by Jared Khoury. As the new branch manager, Jared will drive continued technical improvement and commercial growth within the Cape Town market. Originally from PCS in Durban, Jared unfortunately remains an ardent Sharks supporter!

The PCS team has a strong group of leaders within its organisation and appears to be an exciting business to be a part of. Well done to all involved.

www.performance.co.za

Lumotech diversifies with non-automotive lights Lumotech of Uitenhage is in the process of taking its skills at lighting component and reflector production into markets outside of the automotive sector, where it has long been a leader. The company, formerly known as Hella SA, is using its core skills – of injection moulding, vacuum metallizing and particularly inplant assembly – to produce a range of factory lights as well as street lights, both 22 AUGUST / SEPTEMBER 2014

new markets for the business. Seen here is an energy-efficient warehouse aisle light that is suitable for factories. The light offers significant electricity savings, says the manufacturer. The cover is produced in PP and the reflector in polycarbonate; the individual facet orientation of the reflector captures as much of the lamp’s output as possible and re-directs it in carefully calculated zones as required

www.lumotech.co.za

colour

Excellence in consistency

“When you get right down to the root of the meaning of the word ‘success’ you find it simply means to follow through.”

– CFW Nichol

Our 4 divisions: s -ASTERBATCH s 0IGMENTS s 0ASTES 052 06# s ,IQUIDS 0/ 0%4

Contact us: www.performance.co.za GAUTENG: Tel: + 27 11 961 2700 | Fax: + 27 11 961 2799 | Cnr. Koornhof & Essex Roads, Meadowdale Ext. 1, 1401 CAPE TOWN: Tel: + 27 21 928 2800 | Fax: + 27 21 931 9088 | 5 Linus Road, Beaconvale Industria, Parrow 7500 DURBAN: Tel: + 27 31 701 1202 | Fax: + 27 31 701 2296 | Reed Place Maxmead Ind. Park Unit 22, Pinetown 3620 EAST LONDON: Tel: + 27 43 736 2076 | Fax: + 27 43 736 2036 7 | Reitz Avenue, Greenfields, East London Colour Conversations: should you wish to subscribe to our monthly newsletter, please contact Lurika – lurika.joubert@coloursystems.co.za

INDUSTRY NEWS

West African is

new supplier for BOPP films manufacturer Taghleef BOPP Packaging Solutions (BPS) will trade as division of West African Int’l WEST African Group is the new agent for Taghleef Industries in South Africa.

This follows WAG’s recent purchase of the Taghleef agency in South Africa from Flexible Packaging & Exporting Agency.

Taghleef Industries’ films were introduced into South Africa in 2001 by the late Tony Robertse, as the agent for Al Khaleej Polypropylene Oman (KAPLOM) at the time. Marilyn Robertse took over the AKPP Agency in 2003, and in 2006 Taghleef Industries was formed 24

AUGUST / SEPTEMBER 2014

following the merging of AKPP, Dubai Poly Films and Technopack Eqypt. Over the past 11 years, Ti Films has carved a reputation in the industry for quality, service, reliability and has grown to become the largest importer of BOPP films into South Africa.

Based in Dubai, Taghleef Industries operates nine production sites globally.

With such an international footprint, coupled with its expertise in development and innovation, Ti has established itself as a leader in the BOPP industry worldwide. It has capacity of

approximately 410,000 tpa of BOPP and CPP films; it is the largest supplier of imported BOPP film into South Africa.

Duncan Brown is business unit manager for BPS (BOPP Packaging Solutions), the new West African Group subsidiary

See re the M view on iddle BOP P ind East ustr y on p 80

West African Group has formed a new division, BOPP Packaging Solutions (BPS), to handle sales and distribution of the Ti Films.

The wide product portfolio, production capacity and expertise in product development of Ti suggest BPS will be readily able to & $

$

& $ $ #

WAG has now formed a new division, BOPP Packaging Solutions (BPS), which will trade under the umbrella of West African International to handle sales and distribution of the Ti ďŹ lms.

The company is being run by Duncan Brown, BPS business unit manager, and assisted by Angela Van Maasdyk.

Both were most recently involved at Flexible Packaging & Exporting Agency. â&#x20AC;&#x153;The dynamics of the BOPP market in South Africa has changed and by plugging into the WAG distribution infrastructure (nine warehousing facilities in South Africa plus one in Zimbabwe), together with WAGâ&#x20AC;&#x2122;s healthy resources, BPS is in a strong position to service

customers on a stock-and-sell basis, in local currency, as well as servicing the needs of direct indent supply to customers,â&#x20AC;? said Brown.

The wide product portfolio, production capacity and expertise in product development of Ti suggest BPS will be readily able to supply the various specialised BOPP ďŹ lm grades now being used and efďŹ ciently service the growing market. www.ti-ďŹ lms.com www.westafricangroup.co.za AUGUST / SEPTEMBER 2014

25

Leading the way – Prominent women in South Africa’s plastics industry THE industry has long been mainly male-dominated, but – surprise surprise! – the scenario has changed to the point where the industry’s image is now being, well, more attractively presented.

The unexpected change came about over the last decade or so largely as a result of the emergence of the various sectorial associations, which in turn had been prompted by the need for the industry to self-regulate.

Self-regulation was originally adopted as a strategy to avoid State environmental protective ruling, with the plastic bag legislation of 2002 being fresh in the minds of many.

Virtually all the ‘new’ sectorial associations formed since then have opted for female management. But the appearance of PETCO (for the PET sector), POLYCO (poly-

Leading ladies – Back: Adri Spangenberg, director of the Polystyrene Packaging Council; Mandy Naude, CEO of the Polyolefin Recycling Company and Monya Vermaak, marketing and communications executive, Plastics│SA. Front: Delanie Bezuidenhout, CEO of the Southern African Vinyls Association and Kirtida Bhana, training executive at Plastics│SA. Unfortunately not present for the photo are Annabé Pretorius, South African Plastics Recycling Organisation and Cheri Scholtz, CEO of the PET Recycling Company

olefins sector); the PSPC (Polystyrene Packaging Council); SAPPMA (Pipe Manufacturers); SAPRO (plastics recyclers), SAVA (for the PVC/vinyls sector); and the rebranding of the umbrella body Plastics|SA (formerly the Plastics Federation) was not simply a window-dressing exercise: the women who have been tasked with managing these entities have had to take responsibility for the full representation of their various materials’ public exposure.

Here we look at what these women do and how they go about it.

Delanie Bezuidenhout, CEO Southern African Vinyls Association (SAVA)

Life Li fe is is li like ke a ccam amer am era er a... FFoc a... ocus oc us o on n wh what at’s at ’ss iimp mp por orta tant ta nt,, ca nt capt p ur pt ure e th the e go g od ttim imes im es,, es deve de velo ve lop lo p fr from om tthe he neg neg egat ativ at ives iv es a and nd iiff th thin ings in gs d don on’t’tt w on wor orkk ou or outt, t, ttak ake ak e an anot othe ot herr sh he shot ot!! ot

FEATURE

Business philosophy Live in such a way that if someone spoke badly of you, no one would believe it. Treat your reputation as if it were more valuable than gold. Always help others out, and never speak badly about other people.

What got you to this key position?

I’ve always had a passion for the environment and even when I was in the SA Navy, I tended to gravitate towards projects that focused on protecting our marine environment. As CEO of SAVA my key focus is on guiding the South African PVC industry towards greater product stewardship. It is important to harness your confidence and believe in your abilities. Success doesn’t come without effort – you have to go the extra mile every day and make no exceptions! You also have to be alert and be keyed in to your environment to ensure that you don’t miss opportunities. And ultimately you have to persevere. Successful people also fail, but as times get hard,

Our ‘leading ladies’ enjoyed a morning at Mangwanani Spa at Zevenwacht wine estate. Thanks to the following for helping make the experience memorable: 26 AUGUST / SEPTEMBER 2014

their stamina does not wane. You have to develop a willingness to work through the challenges you encounter along the way.

What do you draw on for inspiration and motivation?

The feeling and intention that I can make a difference is probably my greatest motivator. I want to know that I contributed in a way that will make a sustainable impact or will leave a lasting legacy towards an industry, organisation or for future generations.

Challenges and opportunities?

Product stewardship is a powerful concept that challenges all companies to take responsibility for the products they make and consume. Through strategic leadership over the past four years SAVA have combined the principles of shared responsibility, lifecycle thinking, awareness, innovation and supply chain communications in the PVC industry and embarked on

Rod Wannenburgh TapeTown Productions cell: +27 82 900 2208 rod@tapetown.co.za www.tapetown.co.za

Mangwanani at Zewenwacht Tel: +27 21 903 7427 Cell: +27 82 314 4519 info@mangwanani.co.za www.mangwanani.co.za

the journey to achieve the key commitments of the SAVA product stewardship programme (PSP). Our challenge for 2014 and beyond is to ensure greater representation and participation throughout the PVC value chain on all aspects of product stewardship.

Lessons you have for other women coming up through the ranks?

You don’t have to be a man in a man’s world to succeed. You can be proudly woman! It is important to strike the right balance between work and family life without the guilt. Be confident and most importantly be prepared whenever you go into a meeting. The value of good written and oral communication can’t be underestimated. If you’re passionate about your career, it will make putting time and effort into it pleasurable, not a chore.

Annabé Pretorius, South African Plastics Recycling Organisation (SAPRO)

Hard Ha rd w wor orkk al or alwa ways wa y payys of ys off! f!

Business philosophy Get the job done!

What got you to this key position in the plastics industry?

I found myself without a job after I resigned from Plastics│SA (then the Plastics Federation of SA) and PCA. I always enjoyed the challenges of extrusion. As raw materials, recycled material is a fascinating family on its own. Some recycling surveys during my time at the Plastics Federation brought me in close contact with the recyclers and I knew that they were in urgent need of some formalised structure. On top of this, I like to put my nose in other people’s business and the recycling industry gave me the opportunity to still be involved with many of the other industry sectors. Putting all of this together gave me the opportunity to work with plastics entrepreneurs on a technical basis as well as an industry interaction level.

What do you draw on for inspiration and motivation?

A smiling face somewhere in a factory and a handshake and the words “you taught me, long ago”; a product on a shop shelf that I’ve seen in rough make-up somewhere in a coffee shop discussing the most suitable material and process; a phone call that says “you won’t remember, but you assisted us long ago, can you help again?” A courier at the gate with flowers and a

note that says, “It worked!” When it flies, I fly!

What do you see as the biggest challenges facing you/your organisation?

Combining my hobbies (what hobbies!), my young son, my husband and my only other social interest (volkspele) with a very challenging career! For SAPRO, the challenges lie in doing what we as recyclers have been doing for decades, but doing it better!

What do you view as the greatest opportunities facing you/ your organisation?

The world and his brother are on the ‘green’ bandwagon and if we can’t pull the momentum towards mechanical recycling and reap the benefits now, we never will! The brand owners, retailers, consumers and even the plastics industry are ripe for recycling. SAPRO members need to get in there quickly with better quality and lots of it.

Lessons you have for other women coming up through the ranks?

Stay true to yourself, believe in yourself and grind it – hard work always pays!

Mandy Naude, chief executive officer of the Polyolefin Recycling Company (POLYCO)

Gett in Ge invo volv vo lved lv ed a and nd b be e op pen tto o le lear arni ar ning ni ng g. No Noth thin th ing in g ea earn rnss yo rn y u mo more re cred cr edib ed ibil ib ilit il ityy th it than an spe spe peak akin ak ing in g fr from om e exp xper xp erie er ienc ie nce nc e. e.

Business philosophy Focus on three things: What can you be the “best in the world at”; what are you passionate about, and what drives your company’s economic engine. By consistently focusing your strategy and ongoing business activities where these three areas intersect you will turn your business from a good business to a great business. (Based on Jim Collins book “From Good to Great”) What got you to this key position?

The knowledge and experience I’ve gained during my 25-year career: From market development manager engaging with the total textile value chain, to business manager responsible for a manufacturing operation and global export sales, to supply chain manager responsible for logistic operations and procurement, and finally to divisional manager for a national food ingredients distribution business focused on repositioning strategy to improve profitability and build a professional brand.

The POLYCO CEO position requires every one of these skills and experience.

What do you draw on for inspiration and motivation?

The vision of “zero waste to landfill” for the future, where waste is recycled to create a circular economy and what can’t be recycled is beneficiated to create energy or fuel. As a mother of three daughters, my motivation comes from the fact that I want to be a strong role model for them and show them that if we are passionate about what we do, we can achieve great things and can make a positive difference in the world.

Challenges & opportunities?

Challenges include signing up all remaining converters to pay the voluntary recycling levy to raise sufficient funds for the support of projects to achieve the IWMP targets. To develop close working relationships with the brand owners and retailers to encourage then stipulate sustainable supplier practices like EPR commitment. The “Zero Plastics to Landfill by 2030” strategy will require a partnership approach by everyone in the value chain to increase current recovery and recycling rates. Also, stimulation of sufficient end-use demand to consume the increased recycled tonnages over the next 5 years.

Opportunities include the ability to fund projects that will grow plastics recycling in SA to achieve the IWMP target of 35% by 2019. This means a growth of 80 000 tons of recycled polyolefins. Another is to support reclamation of energy projects and target the non-recycled plastics to achieve zero plastic to landfill by 2030.

Lessons you have for other women coming up through the ranks?

Always be true to yourself and your values. Bring your passion to the role and empower the people around you. Don’t be afraid to have a voice – it is important to be heard if you have something valid to contribute. Get involved and be open to learning, nothing earns you more credibility than speaking from experience. Be professional in everything you do as it builds your personal brand and credibility.

27

FEATURE

Cheri Scholtz,

Kirtida Bhana,

chief executive officer, PET Recycling Company (PETCO)

training executive, Plastics│SA

The Th e wa wayy in whi whi hich ch you do do busi bu sine ine ness ss iiss as iimp mpor mp orta or tant ta nt if if nott mo no more re iimp mpor mp orta or tant ta nt ttha han ha n reac re achi ac hing hi ng ga all ll you ourr go g al alss.

Business philosophy PETCO and I as the CEO follow a simple business philosophy; to devote ourselves to deliver sustainable solutions that contribute to a better environment in SA and opportunities for job creation and growth.

What got you to this key position in the plastics industry?

Long ago, I was on the board of Cape Town Tourism and the CEO was Sheryl Ozinsky. When Sheryl left the organization she was approached by Greg Morse of PenBev to set up PETCO. Sheryl asked me to join her – that was 10 years ago! It was an opportunity to bring about change every day by understanding where packaging comes from and how it has been made and importantly, what happens to that packaging once we have separated it from our refuse and sent it for recycling, the opportunities to use post-consumer plastic in all kinds of new and useful ways and to create jobs in the process.

What do you draw on for inspiration and motivation?

I am lucky to live close to the sea which has a calming and grounding affect. But apart from that, I have been privileged to work with some incredibly dedicated members whose contributions have enabled PETCO to expand its collection network, fine-tune its programmes and strive for ever increasing recycling tonnages. I’m also fortunate to participate in three international networks, The European Plastics Recycling and Recovery Organisation, The Global Alliance for Recycling and Sustainable Development, and recently the Global Product Stewardship Council – we are able share and exchange ideas and solutions.

Challenges & opportunities?

The challenge of creating awareness amongst consumers, working with the industry to design packaging that is recycling friendly, researching new end-use products that can be made from recycled PET (rPET) and facilitating dialogue with municipalities and communities about collaboration. There is a large portion of bottles which will need a viable end-use and new recycling capacity to be installed.

Filling this gap with an end-use is the first challenge. The largest challenge, however, is in collecting the bottles. This will require innovative thinking and a step change in the industry’s approach to bottle collections. The step change will come not just from within the PET recycling industry, but from the wider paper and packaging recycling industry as a whole, including necessary government support.

Lessons you have for other women coming up through the ranks?

Make mistakes, learn from them, be true to yourself, don’t hold grudges, always build bridges and think more about others than you think about yourself. Have the right people in your organisation and always keep the big picture in mind. If you don’t know how to do something, find someone who can help.

28 AUGUST / SEPTEMBER 2014

You Yo u cr crea eate ea te you ourr ow own n worl rld ld ar arou ound d yyou ou.. ou Alll yo Al your ur ttho houg ho ught ug htss, ht s, acti ac tion ti onss an on and d wo word rdss rd creatte tth he world ld you live in. Take responsibility for it!

Business philosophy Great leaders in business are enterprising and innovative. They see the opportunities in especially ‘negative’ climates; they know who to have as allies; they know how to influence policies and legislation and they don’t lose sight of the changing needs of customers.

Great leaders know where to invest their time and money and are always two steps ahead of the game. They are great strategists who use a combination of intuition and influence to guide their next move.

What got you to this key position in the plastics industry?

I literally ‘grew up’ in the plastics industry on a bursary from Megapak to study Plastics Technology. My love affair with science and technology is now combined with my passion for developing employable skills in people.

What do you draw on for inspiration and motivation?

Yoga, meditation and a very strong inner voice.

What do you see as the biggest challenges facing you/your organisation?

Business needs to be friends with government in order to get the best out of the relationship. It is supposed to be a synergistic relationship that creates a win-win situation. Too many judgements and mistrust on both sides does not create the perfect climate for the Industry to prosper.

What do you view as the greatest opportunities facing you/your organisation?

The challenges are also opportunities – so finding some middle ground and the right progressive and industrious people to deal with on both sides would work in favour of the industry.

Lessons you have for other women coming up through the ranks?

Be true to yourself. Be courageous and bold. Do what you are passionate about as a job. Never sell yourself short as a woman because you grew up in a patriarchal society. Network!

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FEATURE

Adri Spangenberg, director, Polystyrene Packaging Council (PSPC)

Posi Po siti si tive ti ve tthi hink hi nkin nk ing in g se sees es tthe he iinv nvis nv isib is ible ib le,, fe le feel elss th el the e inta inta in tang ngib ng iblle ib le and d ccan an ach chi hie ieve tth ieve he iimp he mpos mp ossi sibl ibl ble e… e…

Business philosophy I am always conscious that whilst I’m treading on Mother Earth I also have a duty to make a positive change in the lives of others everywhere I go. Thanks to my work through the PSPC I can create or be on the lookout for new opportunities or find solutions that make a positive impact on our environment, and improve the lives of others at the same time. The South African recycling industry has come a long way during the last five years and we have made major breakthroughs with regards to the recycling of polystyrene, but the challenges we face remain very complicated. By combining my two passions, I truly believe that polystyrene can be recycled sustainably.

What got you to this key position in the plastics industry?

My passionate belief that polystyrene can be recycled sustainably, never giving up on this belief and grabbing the opportunities that cross my path to make this a reality, with both hands.

I also believe in building lasting relationships with the people who come across my path, never burning bridges, and always opening new doors.

What do you draw on for inspiration and motivation?

My determination to find solutions and forming partnerships with key people who have the same focus, goals and “can do”

attitudes make this journey enjoyable and inspire me to do even more.

Challenges & opportunities?

Getting South Africans to recycle in their everyday lives! I also firmly believe that we need laws in place to support the recycling of all materials, and putting structures in place to ensure that recycling is done effectively. Building on our current polystyrene recycling and social responsibility projects and rolling them out to every province and town in our country. The scope of where we can go with these projects (i.e. Breadtags for Wheelchairs, Tutudesk, Wonderbag and the construction project), is enormous. Whilst our projects are aimed at recycling and conserving the environment, they are also touching the lives of somebody else through donating a wheelchair, a desk or a cooking device to those who desperately need it.

Lessons you have for other women coming up through the ranks?

Work hard, never give up, and always grab the opportunities that come across your path with gusto and enthusiasm.

Monya Vermaak, marketing and communications executive, Plastics│SA

Load Lo adss of h ad har ard ar d wo work rk + a an n eq qua uall am amou ount ou nt o off crea cr eatiivi vity ity + a lliit ittl tle le bi bitt off fun fun = M MAG AGIC AG IC..

IC Business philosophy “Work for a cause, not for applause. Live life to express, not to impress. Don’t strive to make your presence noticed – just make your absence felt.”

What got you to this key position in the plastics industry?

I think the 20 years of experience in the communications, marketing, advertising and media field working for various different and ‘difficult’ industries including South African Parliament, the US Embassy, Armscor and the Tswhane University of Technology, helped get me where I am today.

In 2011, the then Plastics Federation of South Africa was seriously in need of a facelift. A new constitution, a new name, a new logo, a new brand identity and a real sense of purpose was needed. I was employed to tell the plastics story, to manage the Plastics|SA brand and the plastics industry’s reputation, to share relevant industry issues with industry role players and disseminating industry news to the media and the general public to clarify misconceptions.

What do you draw on for inspiration and motivation?

I surround myself with positive people, people who are creative, coming up with new ideas and who enjoy life. Nature also inspires my creativity. If all else fails, I allow myself to sit still and start daydreaming, then to start writing anything down that comes to mind, it helps to get the creative juices to flow.

30 AUGUST / SEPTEMBER 2014

Challenges & opportunities?

The SA plastics industry has set itself the ambitious target of eliminating all plastic from the country’s landfill sites under the title: Zero Plastics to Landfill by 2030, which will greatly influence the plastics industry’s strategic direction over the next 16 years. For me this is probably the greatest opportunity and maybe also the biggest challenge. A number of industry role players and government still need to agree on a combined plan of action to eliminate plastic waste in SA. Ongoing engagement regarding legislation, regulations with national, provincial and local departments is top of the agenda. Access to the solid waste stream is essential if we are to succeed in meeting our target and therefore more separation at source initiatives needs to be in place in order to increase the recycling rate of plastics.

Lessons you have for other women coming up through the ranks?

Be guided by a strong commitment. Value honesty and integrity in all your relationships, dealings and transactions. Believe in treating all people with respect and dignity. Don’t be afraid to take risks, even beyond existing boundaries. Trust your instinct.

Don’t allow people to bully you. Be true to yourself. Always!

SA pangolin seized in Chinese scrap plastic import Quantity and quality of material leaving country is having negative effect on recycling sector SOUTH African plastic recyclers have been struggling to buy in collected material due, apparently, to the big demand from China – and the fact that Chinese buyers pay in cash.

Sizeable amounts of cash are required to purchase large volumes of plastic material, even so-called ‘scrap’ such as post-consumer material, and it’s doubtful that many recyclers would be able to pay for large volumes of collected material in cash. But this appears to be no problem for the Chinese agents, a trend which has created suspicions that the trade with China is irregular. This was borne out in early June when customs authorities in Hong Kong made the largest seizure worldwide of endangered African pangolin scales when they discovered more than 1000kg of scales in a shipping container of PET that originated in South Africa.

According to a report from the Hong Kong Special Administrative Region, customs officers doing an inspection for risk assessment discovered the pangolin scales concealed in 40 of the 510 bags of PET in the shipment, and impounded it for investigation.

The seizure at the Kwai Chung Custom House examination compound is estimated to be worth R5-million, the largest seizure of pangolin at Hong Kong’s port in five years. The cargo was not listed on the shipping manifest and it was not clear at which port the container was loaded.

This most recent seizure comes amid concern over the growing levels of illegal trade in pangolins and other threatened wildlife species. International trade in pangolin is banned under the Convention on International Trade in Endangered Species of Wild Fauna and Flora (Cites).

But with prices and the demand for pangolin flesh and scales high in China, illegal wildlife trafficking syndicates are prepared to take risks. According to Hong Kong law, any person found guilty of importing unmanifested cargoes is liable to a maximum fine of $2-million and imprisonment for seven years.

In another relatively recent case, Hong Kong customs officials using x-ray equipment intercepted 33 smuggled rhino horns concealed in scrap plastics in a shipping container in November 2011. It is not known if South African

customs officials utilize such equipment, but the trend suggests this is urgently necessary.

Darren Pieterson, chairman of the African Pangolin Working Group, said the shipment could account for the illegal poaching of more than 300 endangered Temminck’s ground pangolin.

“This trade is having catastrophic effects on the populations of all of the remaining eight pangolin species worldwide, with the Asian pangolin populations showing dramatic declines in recent years. Illegal trade is rife in central and west Africa and was known to occur at low levels in southern Africa prior to this incident. This most recent seizure indicates that illegal trade is widespread in southern Africa as well, and is far from being sustainable,” Pieterson said.

Chemipol expands, buys additives specialist

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AUGUST / SEPTEMBER 2014

Johannesburg materials suppliers also appointed agent for Everspring CHEMIPOL Solutions has broadened its material supply portfolio through the purchase of Keniplas, a supplier of a range of additives and processing aids into the polyolefins and PVC converting sectors.

Chemipol Solutions supplies specialised additives and pigments into the coatings, plastics and printing ink sectors.

Now in its 15th year of operation, Chemipol Solutions is involved in markets across East Africa. It was also recently appointed as the local distributor for Everspring Middle East of Bahrain. Everspring manufactures antioxidants and light stabilizers.

Keniplas was established in 2008 by Ian Clark, a man who has experience in the material supply sector dating

Ian Clark’s company Keniplas and James di Blasio’s business Chemipol Solutions have joined forces. Chemipol is a well-diversified additive and materials supply business operating out of Founder’s View, Edenvale

INDUSTRY NEWS

Local recyclers cannot compete with prices paid by Chinese buyers We asked Jaco Breytenbach, chairman of SAPRO (Southern African Plastics Recycling Organisation), about he was aware of the phenomenon of collected plastic scrap in South Africa being exported to the Far East.

The pangolin is a harmless creature (also known as a scaly anteater) which occurs in eight different species in tropical regions of Africa and Asia. It is mainly nocturnal and specialises in eating ants and other insects. For reasons not comprehended in Africa, its scales and flesh are considered a delicacy in China

Wildlife trade monitoring service TRAFFIC, which records illegal seizures worldwide, called the situation over insatiable demand for pangolin meat in China ‘desperate’. It foresees an increase in African pangolin hunted for the Asian restaurant market.

It estimates that 8000 pangolins were traded last year, and 117,000 to 234,000 were illegally traded between January 2011 and December last year. These are very high numbers for species that occur in relatively low numbers.

back to the time of Lewis & Everitt group in the 1980s. Keniplas needed a partner to expand newly acquired agency and distribution business with investment on biobased plasticizers and purging compounds, and Chemipol was the perfect fit, said Clark.

So the opportunity to blend the agencies into the Chemipol business is a positive outcome for both Clark and Chemipol MD James di Blasio.

Chemipol supplies organic and classical pigments from China and Korea; hyper-dispersion levelling agents and anti-foams for the plastics and coatings industries; titanium dioxide for the plastic and coatings industry.

www.chemipol.co.za

Do you know if cash is being paid for plastic scrap for export to the Far East?

Most of the Chinese buyers are paying only cash, although some others are offering any payment method, cash, cheque, EFT etc.

The Chinese nationals are driving around to collectors of recyclables offering them much, much higher prices Jaco Breytenbach of than what the local industry can afford to pay. The Transpaco Recycling Chinese buyers are exporting this material to the East, is not happy with thus buying in ZAR and selling in US$ and paying the recent trend VERY little for the shipping from SA to the East. This is where good collected material is leaving the why they can pay so much more than the locals. country. Conversely, This has created a short supply of raw materials it is not legal to (scrap plastic) to the polyolefin recyclers over the import plastic scrap past 6-9 months. Further to this, the quality of the raw into South Africa material available to the local recyclers is atrocious.

The best quality is sold to the Chinese at the higher prices and the ‘scraps’ are available to the locals.

Is it possible that the export of plastic scrap from South Africa is being used as a ‘cover’ to smuggle illegal goods out of the country?

I don’t have any proof, but I have heard people speculating that even rhino horn get smuggled to the East, hidden away in the bales of scrap plastic.

The value of the collected scrap, in our estimation, couldn’t be more than R8000 per ton, a lot less than the estimated R5-million worth of the pangolin scales?

The R8000 per ton quoted is more like in R2500-R4000 per ton, depending on the type/quality of the material.

The issue for recyclers is the disappearance of the raw materials, the spiralling cost thereof and the subsequent effect on their businesses and the possibility of job losses. However, as concerned citizens and nature lovers we are also concerned about the irresponsible killing of so many animals to satisfy the greed of some humans.

Sync Tooling repairs moulds Laser mould repair – Sync Tooling & Project Solutions of Uitenhage offers laser repairs to moulds as a core service. Here we see the company’s MD, Geoffrey Hoppner, with a recently repaired injection mould. Sync also offers the mobile unit for in-house repairs at customer sites. As its location in Uitenhage suggests, the bulk of Sync’s work at present is in the automotive sector. Sync is, however, looking at wider horizons, said Hoppner. It also handles graining repairs, offers comprehensive CNC machining, full design service and is the SA agent for hot runner supplier Synventive. It is able to work on tools up to 50 tons in weight, which is not common in SA

www.synctooling.co.za AUGUST / SEPTEMBER 2014

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ASSOCIATION NEWS

Rotation 2014 draws delegates from around roto world Open discussion seems to be popular with foreign delegates

ARMSA’S Rotation 2014 conference kicked off in Cape Town recently with a significantly increased number of international delegates, suggesting that the South Africa rotational moulding event has become globally popular.

The conference took place on 29 and 30 May at the Vineyard Hotel in Cape Town.

It was anticipated at the outset that Cape Town’s recognition as the ‘world design capital’ would attract delegates, but the international delegates may have simply wanted to learn more about roto moulding technology – since there appears to be noticeably more open debate about roto technology at the ARMSA show than comparable events worldwide.

The international delegates – from Australia, India, Ireland, Norway, Kazakhstan, New Zealand and Turkey (Botswana is not considered international enough) – appear to see the open discussion fostered at the Rotation shows as well as the interaction with South African roto moulders (who tend to talk openly about their experience) as an opportunity to learn more about roto technology in a relatively short time.

Rotation 2014 was ARMSA’s 19th successive annual event, so the association has packed a lot into its short life to date.

Ninety-four delegates were present, up from 75 last year, with over 60% of the delegates being moulders.

Opening the show, ARMSA chairman

Keynote – Martin Spencer of Rototek of England was the keynote speaker at Rotation 2014; here we see him with ARMSA chairman Wayne Wiid.

Martin was value for money, giving a number of presentations over the two days of the conference where he discussed solutions developed

by Rototek for technical challenges – which proved useful and interesting for delegates

Wayne Wiid confirmed that the association has grown, with membership up from 40 to 43, after a bit of a dip in recent years.

Tank standards The perennial issue of tank standards also received attention at the outset, with Rod Cairns advising that some progress has been made in cooperation with the SABS. The production of water tanks is at the heart of the roto sector in South Africa, as it is throughout Africa, where poor water supply is a big problem (ironically even in countries with

Product of Year winners keep it cool THERE were a smaller number of entries in the ARMSA Product of the Year competition at Rotation 2014 than has been customary, but quality made up for quantity this year!

What’s becoming increasingly evident is that the full challenge of introducing a new product, and winning awards, needs to be backed up with a solid marketing plan to ensure longterm success for the products.

The euphoria of introducing a new product can have a sobering outcome down the line when sales don’t match projections, but the top SA roto moulders appear to be aware of this danger.

Pioneer Plastics, winning the trophy for the third year in a row, has proven success in this area: it has matched its production of long-range fuel tanks and infrastructure with other contracts for automotive manufacturers. And its 34 AUG / SEPT 2014

Silver medal for its jetty system was a reward for the completion of the entire inter-related jetty system, which first appeared on the market seven years ago.

Cape Town roto moulder 4EVER’s development of its ‘ColdCart’ cold carriage system for logistics suppliers to the retail sector was also evidence of a fully coordinated project, and there is a strong prospect of orders we hear.

Lastly, Accelerate Design continues with its stream of product developments: this year, with his roto-moulded Buffalo Feeder, Piet van Niekerk is finding himself at wildlife auctions quite frequently. Wildlife stud sales are becoming very high value markets, and Piet’s feeder is a good solution for game management, in situations where transported antelope are held in bomas before and after relocation. So it will be satisfying to see success here too.

GOLD

Pioneer wins yet again

Hat trick! – Pioneer Plastics was at it again at Rotation 2014, winning the Gold Medal in the Product of the Year competition for the third year in succession. The roto moulded partition for Nissan’s NV350 panel van provided a weight saving and more efficient solution for the automotive manufacturer.

It replaces a metal cage used previously. Pioneer’s complex solution involves a roto moulded LLDPE casing moulded with brass inserts and a PU foamed core. Tight tolerances are necessary with this moulding (the component is about 1.6m wide, but variations of only millimetres were allowable), so a CNC cut aluminium mould was produced. Pioneer specialises in custom moulding along with a wide range of industrial products, and its skills at post-moulding assembly and fine detail finishing enabled it to produce this high standard item. www.pioneerplastics.co.za

Attorney Rina Gunter gave a follow-up to her previous Rotation presentation, ‘Turning Ideas into Assets,’ in which she outlined how product manufacturers can register their intellectual property (IP) developments as patents, registered designs, trade marks, copyright, domain names, confidential information, know-how and trade secrets or other special categories of rights.

This is a complex field where manufacturers need to protect their rights. Up till now, most roto companies have been open-minded about design rights, but the tough business climate currently is resulting in more protective attitudes

high rainfall). Cairns has been heading up an ARMSA tanks standards sub-committee and says the good news is they now have a ‘home’ at the SABS, where discussions about the setting up of standards structure have taken place.

But the not such good news is that it’s taking a long time and it’s also become apparent that the costs may be substantial. This sounds much like a continuation of the trend with the tank standards programme over the past decade or so, where finalization has remained elusive. Thanks are due to Rod and Grant Heroldt.

Keynote speaker Martin Spencer of Rototek of the UK was the keynote speaker at Rotation 2014. Now in its 21st year of operation, Rototek is one of Britain’s top roto moulders, specialising in the production of sailing craft and kayaks as well

SILVER Roto moulded jetty – Pioneer also sneaked off with the Silver Medal for its roto moulded jetty. It was the Rosslyn company’s founder and MD, Jack Wiid, who came up with the idea of producing jetties utilizing roto moulded floats and fenders back in 2007.

At that stage the surface was made out of planks made from recycled plastics and the structure of galvanized aluminum. But the project has evolved considerably since, partly because a variety of other inter-related components were required for the floating jetty to function as a unit. Items such as buoys, bumpers, hand rails and gangways are necessary, all of which are now included in the Pioneer package. And the surfaces of the floats are now embossed and textured to prevent slipping (a potential hazard with wet plastic surfaces). The award was just recognition for Pioneer’s completion of this complex undertaking – well done guys. www.pioneerplastics.co.za

Cool it! – Dr Gareth McDowell (right), the 493K cooling expert from Northern Ireland, gave two presentations at Rotation 2014; here we see him with Greg Holmes of West Coast Poly of Australia and Henk Scholtz of Africa Design Services

Duys team – Grant Heroldt and Henk Duys of Duys Rotomolders were upbeat as usual. Henk has been involved in wage negotiations with the unions and gave a brief summary to the employers in the audience (which was most of the delegates). One of the salient features was that the employer group, for possibly the first time, in 2014 made demands on the unions, with regard to productivity particularly, which apparently came as a surprise to the union delegates

as a wide range of industrial components. It currently makes about 200 boats a year.

Martin, who studied engineering and worked as an engineer, later went on his own in a business making GRP kayak paddles, which led to him joining Rototek … and a career totally immersed in roto moulding. Martin was an engaging speaker who clearly outlined the complex technical challenges faced at Rototek and the novel solutions achieved.

Rototek installed its first automated large roto machine, a Leonardo unit from Persico of Italy, in 2005 – as a result of which it is now able to mould parts up to 7m wide, including foam sandwich structures. Its biggest moulding to date is a 28,000-litre tank where the shot weight was 950kgs (the wall structure at the base is 25mm thick).

According to Martin, the key for successful roto moulding is teamwork, detail, planning and patience!

It’s welcome back to Petro Geldenhuys, who was for years the organizer of the Rotation conferences: she’s back and everything ran smoothly at the 2014 event. Here we see her with inimitable Gary Lategan of RotoSolutions, who’s refined his presentation further. Basically, the most important thing in roto moulding is to do it faster, “the faster we go the better,” said Gary

Clive Robertson of ACD RotoFlo gave his annual review of the regional roto moulding sector, looking at trends and consumption figures, while Rod Cairns of JoJo was again quite ruthless in his role as chief fund-raiser and auctioneer extraordinaire – on this occasion Rod managed to extract a total of over R15,000 from the poor delegates … but it was all for a good cause: the funds have been donated to the Jacaranda Childrens Home in Pretoria

BRONZE Coldcart – 4EVR Plastics’ ‘Coldcart’ mobile cold transport unit is designed to move food products and other temperaturesensitive goods where the ‘cold chain’ temperature remains consistent. Designed to look like a block of ice, the twin-skin compartment with polyurethane foam insulation was developed in cooperation with dry ice manufacturer Sidewinder. Crates fit snugly into the compartment. 4EVR, a Cape Town-based roto moulder, encountered initial problems with delamination between the PU foam and PE structure, but overcame the challenge. In one test, a Coldcart carrying ice cream was left outdoors in the Boland in summer, with daytime temperatures in the 30°C range, and product temperature over the 48-hour duration of the test ‘declined’ from minus 18° to minus 10° – a result which the retailer was very happy with. www.4EVR.co.za

4EVR team – The team behind the development of the Coldcart includes George Lotz, Simon Botha and Vonnie Heyns of 4EVR. Vonnie, the spokesman for 4EVR, said the cart was receiving a positive reaction from retailers

Buffalo/Sable Feeder – The Buffalo/ Sable Feeder from Accelerate Design is an automated supplementary feeder for game farms and specifically game breeders. A ‘slave unit’ meters out grains or other foodstuffs on demand, as a result of which the 550kg hopper does not to be replenished daily. The sturdily designed units (1.2m high x 1.9m wide) are positioned on game trails or gathering areas in the veld. The product features a solarpowered battery pack and automated time control. Piet van Niekerk of Accelerate said it was surprising how quickly game species and goats became familiar with the device and miraculously timed their daily visits to the feeder to exactly the same time of day. The unit was entered in the competition but did not receive an award. www.accelerate.co.za

AUG / SEPT 2014 35

Rototek (UK) specialises in 3-layer moulding Rototek (UK), the company of keynote speaker Martin Spencer, specialises in the production of 3-layer mouldings (inner and outer skin with insulation in the core). Here are examples of some of the key applications he discussed, including å ‘Glink’ basin for Philip Watts Design; ç water filter unit; é emergency cabinet and lifebuoy for Walcon Marine; è ‘Baliza’ plug-in point housing for boat marinas; ê fitting cart for Cleveland Golf; ë ‘Xcess’ kayak for Teksport; í range of ‘Fava’ dinghies; ì ‘Bristol Maid’ bedside locker for the health care sector (which won a number of awards); and î cable access chambers

In 2011 Rototek was purchased by Gusto Group, a business involved in the construction sector.

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the AK47; Airbus A380.

“Good design is aesthetic. Good design makes a product understandable, is ‘Good design is simple’ unobtrusive, honest, and long-lasting and is Kees Schilperoort of Xfacta made a welcome thorough down to the last detail,” said Kees. return to the Rotation conference, his previHe gave the example of BMW group’s ous presentation in 2012 having been well purchase of the Mini from Leyland in the received. And his message on this occasion UK: all the German automotive manufacturwas very similar too: “Design is a simple er really bought was the name and badge! matter, and it’s best to keep it as simple as Most of the examples cited were arguably possible,” said Kees. beyond the reach of the roto moulders presHe first looked at what he called the ’20 ent, considerably actually, but the concepts Best Designs Ever,’ which include items that Kees mentioned were definitely relevant. have become common phenomena which The main need is to check out all possible we are all familiar with, including: outcomes with your products … and then the Apple ‘Mac’ computer (introduced in keep it simple.

1984); “Get real, and have a compelling story Vespa scooter – now here’s an item that’s that you can stick with,” said Kees. hardly changed in general appearance since its introduction in Italy in 1946 (“It’s www.xfacta.co.za cool,” said Kees, “and the ability to handle www.vespa.co.za something that’s cool is difficult”); the escalator; www.virgingalactic.com the Virgin ‘Galactic’ space plane;

ASSOCIATION NEWS

www.rototek.com

Paintflex – Akarsu Ahmet of Paintflex showed some of the painting solutions its developed. A Japan-Turkey venture, Paintflex manufactures ‘multi-functional smart paint’ for plastics, fibre-reinforced plastics and metals. According to Akarsu, who was visiting from Istanbul, the paint requires no sanding, blasting, primer or hardener … and yet bright and high quality surface finishes are achieved

Anti-slip performance is achieved on PE or PP roto moulded products, such as this large bin lid, using the Paintflex paints

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The ARMSA committee for the year ahead includes Rod Cairns (JoJo Tanks), Petro Geldenhuys (secretary), Wayne Wiid (Pioneer Plastics, chairman), Peter Lemmer (Calcimite), Grant Heroldt (Duys Rotomoulders), Clive Robertson (ACD RotoFlo) and Gary Bolt (Atlas); Nick Aggett of Sasol Polymers was absent

www.paintflex.com

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At its plant in Newark, England, Rototek operates highly automated ‘Leonardo’ machines from Persico of Italy. The size of the machine obviously allows for the production of large mouldings. Rototek has since 2011 been part of a construction group, Gusto, which has created opportunities for it to do large mouldings such as for electrical components www.rototek.com

‘Cooling workshop’ Dr Gareth McDowell was continuing in the footsteps of a series of roto specialists from Northern Ireland who’ve addressed the Rotation conferences over the years.

His business, 493k, is focused on temperature control for roto moulding, and he’s proposing a new approach to cooling.

Temperature control and particularly cooling

is of greater interest in roto moulding that other plastics processing method, to such an extent that it’s literally a make or break scenario: if products cool too fast they can fail, and if they cool too slowly the can also fail (and both variants can be costly). Besides warpage and shrinkage, crystallinity of the polymer is affected differently by either scenario, which can lead to subsequent failure

of the moulded item.

So the point of release from the mould is vital. But Gareth also reminded delegates of the importance of ambient temperatures.

Temperatures during the day can vary substantially anywhere, and the Highveld in South Africa has a particularly high variance between night and day temperatures – and it’s vital for moulders to factor this in.

AUGUST / SEPTEMBER 2014 37

2012, 2013, 2014 ARMSA PRODUCT OF THE YEAR WINNER SPECIALISTS IN CUSTOM MOULDING We can assist in the design, development, and manufacture of your specific product to meet and exceed your quality requirements.

OUR PRODUCT RANGE INCLUDES: Bins and containers, drums and tanks, road barriers, mobile toilet huts, septic tanks, waste management, and many other products.

www.pioneerplastics.co.za Tel: 012 541 6000/1/2 E-mail: sales@pioneerplastics.co.za

WINNER

Interesting solutions from young designers

First prize – Lwazi Grant of Tshwane University of Technology was the winner of the Sasol Student Design Competition at Rotation 2014, receiving his prize from Brian Sole of Sasol Polymers. Lwazi’s ‘Sechaba Project’ (the People’s Project) is a roto moulded rain water collector, water filter and dispenser that double up as a bus shelter with seating

Sasol Student Design Competition runs for 15th year THIS year’s Sasol Student Design competition again drew an enthusiastic response from the design departments at the Tshwane University of Technology and the University of Johannesburg. Presented for the 15th year in succession, the competition’s reputation has grown and spread, to the point where the standard of the students’ designs is now literally world class.

This year’s challenge was to design a roto moulded bus shelter which needed to be combined with a water harvesting capability. To their credit, the students came up with varied and interesting solutions, which – given that a bus sheltr has limited scope for inventiveness – wasn’t that easy.

The plus for the generally conservatively mind roto moulders (conservative because they need to be: you don’t get paid for ideas) in the audience was simply to view the level of creativity on show.

He also mentioned how important it is to main a rapid changeover cycle, if the “doors of your oven are open for longer than 7-10 seconds, you’ve got a problem,” said Gareth.

ASSOCIATION NEWS

www.493k.com

‘Beyond Form & Function’ Nico Hickley’s presentation must have been of interest to all the delegates, possibly more so for the international visitors – since they may not previously have been availed to such a candid explanation of the challenges faced by a roto moulder (such presentations are usually made by suppliers to the industry).

Nico is effectively a student of the process who’s involved in production and happy to talk about it!

Recent production experience at Nico’s company, CHM Plastics in Midrand, formed the foundation of his presentation.

Year-on-year review Clive Robertson of ACD RotoFlo has been making an active study of the roto sector in Southern Africa for some years. Last year the news for the business was highly positive, based on a significant increase in consumption and new roto business development in the neighbouring states … but the results over the past nine months have been more sobering.

The main factor is the dramatic increase in prices for roto powders: Clive estimates that roto convertors have faced a total price increase of about 38% between December 2012 and May this year.

This has been a major constraint on business activity. The increase is partly due to the reduction in the exchange rate of the rand, which alone may account for close to a 20% shift over the past nine months.

The figures suggest there will be a

slight rise in total tonnage converted – estimated at 1.87% – in total consumption for the sector over the past July-June period.

The figure for 2013 was a record high of 31,100 tons, and it was estimated that that record would advance just slightly by the end of June 2014 (by the end of April this year 26,400 tons had moved).

Besides that, the exit of powder manufacturer Lomotek Polymers from the market earlier this year interrupted production for several manufacturers, although ACD RotoFlo itself was largely able to fill the shortfall following a dramatic plant expansion – coincidentally at about the same time of the Lomotek closure.

Clive suggested that the lower and expected result was at least partly due to what he called the ‘Marikana effect’ as well as the drawn out strike in the platinum mining sector, which has had a knock-on

Product of the Year winner

The Xfacta – Kees Schilperoort of Xfact of Johannesburg spoke about high-end design, focusing on designs that are familiar worldwide, but the lesson for the roto moulders present was valid and real: your designs need to be exceptional, but simple too

Gary Wiid of Pioneer Plastics with the Rosslyn company’s winning entry in the 2014 Product of the Year competition, a partition for the Nissan NV350 panel van

38 AUGUST / SEPTEMBER 2014

3RD PLACE Roof tunnel farming – TUT design student Deon Joubert took third prize for his roof tunnel farming prototype. The roof structure forms a tank to house collected rainwater. Pipes are then connected to the tanks at various points, allowing the farmer to irrigate plants. The roof’s side drops, which form the holding tanks, forms part of the erected structure and can be set at variable heights.

SPECIAL AWARD Sibusiso Nkongwane, a design student at the University of Johannesburg, was the runner-up this year with his design for a roto moulded bus shelter/water harvesting solution, a sturdy solution – which is arguably one of the main requirements for long-term use

RUNNER-UP

effect that’s been felt in the roto sector.

The overall outcome is that the roto market has been ‘flat’ over the past year, but it’s not a contraction.

www.armsa.co.za

Ian Victor and Chris Meintjies of MCG Industries were interested delegates at Rotation 2014

Association of Rotational Moulders of Southern Africa Chairman: Wayne Wiid E-mail: wayne@pioneerplastics.co.za Tel: 012 541 6000 / 082 772 7369 Secretary: Petro Geldenhuys Tel: 082 562 4994 | Fax: 086 509 8909 E-mail: info@armsa.co.za ASSOCIATIONS AFFILIATED TO ARMSA THROUGH ARMO Association Francophone du Rotomoulage Associazione Italiana Stampaggio Rotazionale www.armsa.co.za Association of Rotational Moulders Australasia Association of Rotational Moulding Central Europe Association of Rotomoulders Ireland The British Plastics Federation Rotational Moulders Group

Hein Dubery of TUT received a special award from Brian Sole of Sasol Polymers for his work in tutoring the students in the process of conceiving and developing their designs

AUGUST / SEPTEMBER 2014 39

ROTATIONAL MOULDING

ACD RotoFlo appointed agent for ®

Mold In Graphic Systems ACD RotoFlo, Southern Africa’s youngest and now largest supplier of Colour Compounded Rotomoulding Powders, announced at the recent ARMSA conference that it has been appointed as the exclusive Southern African distributor of Enhancement Products from Mold In Graphic Systems® (MIGS®) USA. Clive Robertson, MD of ACD RotoFlo, has had a long association with MIGS and is excited to have the opportunity to add their unique and useful products to ACD’s product range. Local Rotomoulders will welcome the ready availability of the MIGS product range.

Mold In Graphic Systems is a technology leader known for their valueBoxes for delivery motorcycles operated by pathology lab Ampath branded with added graphic decorating processes decals from Mold In Graphics® – moulded by CHM Plastics of Midrand – achieve and speciality materials. Permanent a visible and long-lasting result graphic systems are supplied to the global plastics processing industry. appearance and functionality of solution to many of the quality issues Established in 1983, the company is threads, increases the strength of experienced by rotomoulders on a daily head quartered in Clarkdale, Arizona, inserts, and eliminates thinning and basis. By creating better resin flow to USA and their Enhancement Products bridging by creating better flow of all areas of the for rotomoulding the resin. In short, it’s a ‘a miracle in mould, Surface are supplied “Mold In Graphics supplies a can’.

Enhancer 360 through a global surface enhancement The MIGS Enhancement Product dramatically network of products for polyolefins line-up also includes RMC3®, improves distributors. applications in blow, the surface a unique rotational moulding Best known conditions of compound giving moulders and injection and roto moulding of the MIGS rotomoulded designers an enormous amount of Enhancement as well as thermoforming.” polyolefin parts. flexibility, allowing them to create Products is Surface It quickly and easily removes ugly unique, solid features on their parts.

Enhancer® 360. Rotational moulders pinholes, voids and blowouts in the Other products include Patch ‘N are constantly striving to produce better surface of rotationally moulded parts.

Go® for cosmetic repairs to damaged products, free from blemishes and Surface Enhancer 360 improves the PE parts, Parting Line Sealer® to defects. Surface Enhancer® 360 is the

RMC3 is a unique moulding compound from Mold In Graphics: it is a ‘putty like’ polymer which bonds and cures perfectly to normal LLDPE powder. It allows moulders to create solid features on parts which would otherwise prove difficult. In the example of the toolbox mounted on this pickup, the production of the lugs to stabilize the lid hinges was made possible through the use of RMC3 PHOTOGRAPHS COURTESY OF WALTEX INDUSTRIES, NEW ZEALAND

40 AUGUST / SEPTEMBER 2014

Fluid Kayaks of Parys on the Vaal River, a manufacturer of kayaks, uses MIGS decals to brand its river craft, achieving long-lasting results in the process www.fluidkayaks.co.za

stop powder leaks in the mould and prevent blowholes forming along the parting line. Color In Systems®, like Mold In Graphics®, embeds itself directly into the resin surface, resulting in completely permanent custom designs. ü

For further information on the MIGS® products, ACD RotoFlo can be contacted on +27 11 708 3361 – sales@rotoflo.co.za / andrew@rotoflo.co.za. www.moldingraphics.com/ enhancement-products

Portable toilets moulded by CHM Plastics with ‘Sanitech’ Mold In Graphics

Decals from MIGS were used to brand the lids of these Hippo Roller water tanks, produced in South Africa, achieving a high standard and long-lasting brand presentation

AUGUST / SEPTEMBER 2014 41

Colour Compounding of Roto and Speciality Polymers Pulverising of Roto and Speciality Powders Agents for MIGS® Clive Robertson Michael Böltau Chanda Mukuka Address:

cliverobertson@iburst.co.za tech@rotoflo.co.za sales@rotoflo.co.za

28 Hilston Road Kya Sands Randburg, Johannesburg

082 880 4976 084 540 2896 011 708 3361 / Fax: 011 708 1919

JoJo supports Wildlands Trust

ROTATIONAL MOULDING

Donates one water tank for every tank purchased JOJO Tanks has added weight to its partnership with the leading environmental NPO Wildlands Conservation Trust by substantially increasing its donation of rainwater harvesting tanks to 500 over the year, with Wildlands purchasing a further 500.

Sixty-nine JoJo tanks were handed over to a group of excited community members (‘Green-preneurs’) in the uThungulu district in KZN in February.

JoJo has undertaken to donate one tank for every tank purchased by Wildlands.

The rainwater harvesting tanks are distributed across the country to Wildlands ‘Green-preneurs’ as part of their sustainable community barter model.

Community members who join the project are taught how to grow indigenous trees (Tree-preneurs) and collect recyclable waste (Waste-preneurs) and when these trees reach a certain height, or their waste is of a significant weight, they can barter this with Wildlands for livelihood support items. JoJo tanks are

a popular purchase option for these Green-preneurs as the tanks provide water security in these disadvantaged communities where formal water supply infrastructures often do not exist.

“At JoJo Tanks we are passionate about the role we should play in conserving our planet’s limited resources,” said JoJo MD Rod Cairns.

“The association with Wildlands provides

us with an excellent opportunity to make a difference where it matters. Saving water should be a way of life and the harvesting and use of rainwater by installing rainwater tanks could grant relief to millions of disadvantaged South Africans. The tanks certainly provide a cost-effective and convenient way for tree-preneurs to care for their trees. We are proud to be involved with this.”

JoJo Tanks’ gesture to donate a water tank for every tank purchased by the Wildlands Conservation Trust is seen as a sustainable community barter model that has benefitted rural communities – and been appreciated too. The group is to present 500 tanks this year, so it’s a major initiative PHOTO: KELVIN TRAUTMAN

www.jojotanks.co.za www.wildlands.co.za

SCG-ICO Polymers, the joint venture between the leading international roto moulding resin suppliers SCG Chemicals Co Ltd and A Schulman Inc, has its focus in growing business in Asia, the Middle East and Africa. This is a fully integrated roto moulding supplier with a wide variety of product, ranging from natural granules, colour and ‘granite’ powders to specialty grade powder such as PE foam, crosslinked compound, flame retardant and high-temperature PP. SCG ICO exhibited some of their latest products at Rotation 2014. The partners are represented in South Africa by MBT. 42 AUGUST / SEPTEMBER 2014

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Ralph Oxenham (1941-2014) that he suddenly died on 23 July. Impalilia means â&#x20AC;&#x2DC;the endâ&#x20AC;&#x2122;, RALPH Oxenham, a man who rose to manage one of the top being the very end of the ďŹ&#x201A;ood plain. businesses in the local plastics industry but who focussed much Ralph had a backbone of steel and will be attention on training, passed away suddenly at remembered for getting the job done, rich in life the lodge he set up on the Chobe River in July. yet a simple life style. He was a leader and yet Born on 2 October 1941, Ralph spent his a handyman who could ďŹ x a pump or unblock early years in Livingstone and at school at a sewage pipe, and he could do anything that Falcon College near Bulawayo, Zimbabwe. He he expected you to do. He loved an occasion earned his nickname â&#x20AC;&#x2DC;Unruly Ralphâ&#x20AC;&#x2122; at UCT to celebrate, whether in the city with French and graduated with a BSc Biology degree, and Champagne or in the wild with the locals and his ďŹ rst job was with the Bechuanaland (now their beer. He had an infectious sense of Botswana) Game Department. From there he humour. He was happy whether it was sitting joined the Zambian Game department. on a plastic beer crate under a thorn tree or His foray into business started in Salisbury, on a leather ofďŹ ce chair in his Sandton ofďŹ ce, now Harare, at Lever Brothers and then with although there is little doubt where he would Mobil who had a wonderful career mapped out Ralph Oxenham was happy whether he was sitting on a have preferred to be. for him before he left to work in South Africa for plastic beer crate under a thorn To his family Ralph was a hero as he took Sentrachem, where he became MD of Mega tree or on a leather ofďŹ ce chair an interest in and supported what they did, Plastics. It was during this time that he was in his Sandton ofďŹ ce whether it was their academic achievements appointed chairman of the Plastics Industry or sport. He showed concern for others and Training Board. displayed many acts of kindness. He impacted upon the lives of After his retirement in the late 1990s, although he did many and testimony to this was the large number who attended continue as deputy chairman of Sentrachem as a subsidiary of his memorial service in Johannesburg.

Dow Chemicals, he returned to his passion of â&#x20AC;&#x2DC;remote Africaâ&#x20AC;&#x2122; He is survived by his wife Dawn, David, Lisa, Gill and Ant and and developed Ichingo Chobe River Lodge together with his their families. wife Dawn. It was in the bush on the remote island of Impalilia

Plastomark champion Pieter Marè of Blinex Plastics of Pretoria was the winner of this yearâ&#x20AC;&#x2122;s Plastomark Open. Here we see the 2014 champion with Zelda Vikos and Wolfgang Raffalsky. Blinex is an injection moulding business

AUGUST / SEPTEMBER 2014 43

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Zero Plastics to landfill by 2030

ASSOCIATION NEWS

Industry aims to drive maximum value of plastics, enhance the reputation of the plastics industry Industry Waste Management Plan,” THE South African plastics industry Hankom said. “Access to the solid has set itself the ambitious target of waste stream is essential if we are to eliminating all plastic from the country’s landfill sites by the year 2030. According succeed in meeting our target, and therefore we are calling for ‘separation to Plastics|SA, the umbrella body at source’ in order to increase the representing the entire local plastics recycling rate of plastics”. industry, a new sustainability objective Seven key areas has been set under the of improvement and title ‘Zero plastics to ‘Access to the solid development were landfill by 2030’, which waste stream is identified to align the will greatly influence essential if we are to plastics industry’s the plastic industry’s succeed in meeting objectives with the strategic direction over targets set out by the the next 16 years. our target, and we are Government’s National “Increasingly scarce calling for ‘separation Development Plan. natural resources at source’ in order to These include: and expensive landfill increase the recycling 1. Developing an space has pushed effective infrastructure recycling to the top rate of plastics’ across the value chain. of the agenda for all 2. Ensuring ongoing research and the packaging streams. The plastics development into new technologies industry is leading the charge by setting and markets. higher than expected recycling targets 3. Establishing credible data sources and getting industry role-players and and information sharing across the government to agree on a combined value chain. plan of action,” said Anton Hanekom, 4. Developing skills to enable the executive director of Plastics|SA. technology and infrastructure.

Plastics|SA’s Sustainability Council, 5. Changing and improving consumer which comprises various polymer understanding and behaviour around associations, such as PETCO, recycling and waste disposal.

POLYCO, PSPC, SAVA and the 6. Developing industry collaboration SA Plastics Recycling Organisation towards the vision.

(SAPRO) as well as major retailers 7. Ensuring constructive and effective and industry leaders attended a engagement and collaboration strategic workshop earlier this year, between industry and government. aimed at developing a united vision and road map for the future of plastic Addressing the shortcomings waste in South Africa. At this meeting, and developing each of these focus the Sustainability Council members areas will take place through a set of voluntarily agreed and committed their organisations to working towards a vision of ‘Zero plastics to landfill by 2030’.

While the plastics industry aims to use this target to drive the maximum value of plastics, it also hopes to enhance its reputation in the eyes of key stakeholders. “One of our main objectives is to enhance plastics recycling in South Africa on all levels through an active and ongoing engagement with key stakeholders such as national, provincial and local governmental departments with regards to waste management legislation, regulations and the recent development of the industry Paper and Packaging 44

AUGUST / SEPTEMBER 2014

achievable objectives within the short term (foundation setting), medium term (building and innovation) and long term (optimising): Where recycling is not possible or difficult, industry leaders have also given their support to use plastics for energy recovery.

“Thanks to its molecular make-up, plastics are an ideal material to be recycled and a resource that is too valuable to simply be thrown away or merely incinerated. The South African plastics recycling industry has developed rapidly during the past few years, both in terms of creating new recycling techniques and creating new markets for recycled products. We have proven that plastic products can effectively be recycled many times over into new products, and are being recognised as one of the world leaders when it comes to “closing the loop”, or recycling products back into new products.

Whilst our first choice will therefore always be to recycle plastics, we recognise that waste-to-energy recovery options could help save natural resources and support our objectives of saving landfill space, reducing litter, saving energy and reducing CO2 emissions,” said Hanekom.

Efforts to combat marine litter up 90%

Douw Steyn, director of sustainability at Plasticsâ&#x201D;&#x201A;SA and chairman of the Outreach and Stakeholder Engagement of the Global Action Team on Marine Debris (GAT)

Over 180 projects internationally Engagement of the Global Action Team on Marine Debris (GAT).

Since initiating the Global Declaration, signatories have identiďŹ ed numerous speciďŹ c actions designed to fulďŹ l these commitments and have agreed to track and report progress. According to the 2013 report, the international plastics industryâ&#x20AC;&#x2122;s efforts boast a 90% increase in projects that combat marine debris (http://www. plasticsinfo.co.za/images/5297.pdf) â&#x20AC;&#x153;It was encouraging to see 60 plastics associations from 34 countries across the globe voluntarily sign the declaration in recognition of the important role they have to play in ďŹ ghting marine litter,â&#x20AC;? Steyn said, explaining that each of these associations launched and support projects in six key areas aimed at contributing to sustainable solutions. The six focus areas of the Global Declaration are education, Marine litter is a growing concern, and more data to properly research, public assess the extent of the problem is needed. Active participation in policy, sharing best the collection of data on plastics litter is key to helping coordinate practices, plastics sustainable practices and behaviour. Plastics|SA is leading South Africaâ&#x20AC;&#x2122;s involvement in this area recycling/recovery,

CURRENTLY there are about 185 projects planned, underway or completed as part of the Declaration of the Global Plastics Associations for Solutions on Marine Litter (Global Declaration), a public commitment by the global plastics industry to tackle plastic in the marine environment. â&#x20AC;&#x153;Plasticsâ&#x201D;&#x201A;SA was one of the signatories of the Global Declaration, which was co-signed by leaders from plastics organizations across the globe in March 2011 at the 5th International Marine Debris Conference in Honolulu, Hawaii,â&#x20AC;? explained Douw Steyn, director of sustainability at Plasticsâ&#x201D;&#x201A;SA and chairman of the Outreach and Stakeholder

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and plastic pellet containment. â&#x20AC;&#x153;This is a tremendous increase in participation, considering where we started,â&#x20AC;? said Steyn. â&#x20AC;&#x153;As an industry, we have an important role in contributing sustainable solutions for marine litter. To this end, Plasticsâ&#x201D;&#x201A;SA hosted the ďŹ rst African Marine Debris Summit last year, and is currently planning a second marine debris summit to take place in Cape Town in June 2015.â&#x20AC;?

15 â&#x20AC;&#x201C; 20 September is Clean-Up & Recycle Week

www.plasticsinfo.co.za

National Recycling Day on Friday, 19 September: encourages schools, business and communities to recycle.

Visit www.mywaste.co.za to ďŹ nd a recycling facility near you.

International Coastal Clean Up Day on Saturday, 20 September: will once again see South Africans from all walks of life participate in one of the worldâ&#x20AC;&#x2122;s biggest volunteer efforts for ocean health. Plastics|SA will once again be coordinating beach clean-ups, as well as similar clean-up initiatives at rivers, streams and water sources inland (visit www.cleanup-sa. co.za for more information).

AUGUST / SEPTEMBER 2014

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Testing time – Coen Burger of the IOM³ Eastern Cape with Ralf Baeuerlein of Montech GmbH of Germany and Jaimie Targett, the SA agent for Montech

Montech’s rubber process analyzer has wide capabilities Real power displayed during dynamic testing

ASSOCIATION NEWS

BY KATHY GARDE

ON 26 JUNE, the Eastern Cape branch of the Institute of Materials hosted a technical lecture evening in Port Elizabeth sponsored by MonTech Rubber Testing Solutions GmbH. Ralf Baeuerlein delivered an extremely informative presentation describing the wide range of materials testing instruments available from MonTech, their diverse applications and capabilities, and their focus on cuttingedge technology and technical support.

Among the instruments showcased was the Rubber Process Analyzer (RPA) for advanced rubber compound characterization using static and dynamic testing. The real power of 46

the RPA is illustrated during dynamic testing, where, unlike with standard oscillating disk rheometers (ODR) and moving die rheometers (MDR), the operator can change the frequency of oscillation and oscillation angle along with the temperature (right down to glass transition temperatures).

This dynamic platform enables the study of properties under different sheer rates, different strain effects and varying rheological conditions, which much more closely mimic the actual conditions experienced by the rubber compound in real-life operation. Some examples of analysis capabilities are the simultaneous study of cure and blowing/foaming reactions in sponge compounds, advanced cure

kinetics modelling, study of structural breakdown of rubber compounds under varying conditions, strain sweep for filler loading Payne Effect, silanization reaction studies, and many more.

The capabilities don’t end with rubber and plastics, though, as the RPA finds many applications in the study of other materials – for example, due to the very low oscillation angles possible with RPA, study of the cure characteristics of ceramics and hard resins is possible.

MonTech is represented on every continent and in over 53 countries, and provides technical and commercial service through a network of highly-qualified local and international support staff.

Contact Jaimie Targett for more info: Jaimie@montechafrica.co.za

AUGUST / SEPTEMBER 2014

SAVE 15%!*

THE ICIS AFRICAN POLYMERS CONFERENCE Tuesday 14th – Wednesday 15th October 2014, Johannesburg, South Africa

SA PLASTICS EXCLUSIVE DISCOUNT Media Partner

www.icisconference.com/africanpolymers

Seizing opportunities and overcoming barriers in Africa’s polymer markets WHY ATTEND?

HEAR FROM INDUSTRY EXPERTS

By attending this unique event, you will: • Analyse the megatrends shaping the plastics industry in Africa and learn where the opportunities lie in the future • Understand global polymer supply and demand dynamics and how these relate to Africa • Identify the demand sectors offering the most promising growth and receive a forecast for the health of these industry segments • Discover the prospects for Nigeria and Kenya – two of the continent’s most dynamic markets, and potentially the most rewarding • Dig deep into South Africa – the region’s most mature market, yet also offering great potential • Assess the progress of plastics recycling initiatives and their impact on markets for virgin polymer Plus much more!

Mani James, Operations Manager, FROST & SULLIVAN SA Anton Hanekom, Executive Director, PLASTICS SA Dick Coates, Managing Director, MBT SOUTH AFRICA (part of MB Barter Group) Secure your place at this intensive and informative conference to improve your knowledge of the polymer industry in Africa and give your business the best chance of success now and in the future!

FOR MORE INFORMATION AND TO REGISTER YOUR PLACE www.icisconference.com/ africanpolymers +44 (0)20 8652 3887 events.registration@icis.com *Quote promo code AZT17419 when registering to secure the exclusive 15% discount Pan African Knowledge Partner

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SAPPMA VIII in September Plastic Pipe in Infrastructure is the theme this year

THE Southern African Plastic Pipe Manufacturers Association (SAPPMA) and its subsidiary organisation, the Installation and Fabrication Plastics Pipe Association (IFPA) jointly welcomed nine new members to their associations recently.

Treger Plastics and the Rare Group have both joined SAPPMA in the pipe manufacturers’ category, whilst Nesstra and Engen joined in the category of suppliers. IFPA has welcomed Waterzone, Alprene, Plasti-Tech, Dynamic Industrial Piping and Procon Africa as new members.

“The growth in our membership bears testimony to the fact that membership to SAPPA and IFPA adds value to individual organisations as well as ensures quality and peace of mind for the end user. By enlarging our footprint, we can speak with stronger voice when it comes to matters that directly affect our industry, ranging from non-compliance to industry standards, to protecting our members against inferior imports. Belonging to SAPPMA and IFPA is a certain way of differentiating the responsible players in the field from those who are reckless about quality and ethics, unlocks substantial benefits to members, and increases marketing exposure for them through being part of a reputable, regulated association,” said Jan Venter, Chairman of SAPPMA. www.sappma.co.za

Conference fee and registration The conference fee is R1 900 per delegate for non-SAPPMA members, and R1 200.00 for SAPPMA member companies.

There is also a special discount structure in place for group bookings of four delegates or more. CPD points are available for professional engineers who are attending the conference.

Registration form and more info can be found on the SAPPMA website. www.sappma.co.za

47

SAPPMA & IFPA welcome new members

Manglin Pillay, CEO of the South African Institution of Civil Engineering Andrew Seidel, Underground Solutions, USA Ulrich Schulte, Prof Kobus van Zyl Farraj Tashman, Borouge, UAE Prof Fanie van Vuuren Colm Lyons, Georg Fischer Schaffhausen, Switzerland Alaster Goyns, Pipes cc Renier Snyman, DPI Plastics Ian Venter, Marley Pipe Systems Mike Smart, Genesis Consulting Jacques van Eck, Klamflex Amit Raga, SABS Kirtida Bhana, Plastics|SA “Our annual Pipes conferences has gained a reputation for being the plastic pipe industry event of the year and we believe this year’s line-up of speakers and topics will once again raise the bar,” Venter added.

AUGUST / SEPTEMBER 2014

THE Southern African Plastic Pipe Manufacturers Association (SAPPMA) will host its annual Pipes VIII conference that will take place on Tuesday, 2 September at the Bytes Conference Centre in Midrand.

“The theme of this year’s event will be ‘Plastic Pipe in Infrastructure’ and we have invited papers around this theme to look at the challenges and opportunities facing the industry, as well as the trends that influence the direction our industry is taking on a local and global scale,” said Jan Venter, chairman of SAPPMA. Pipes VIII’s main sponsors are Protea Polymers, DPI Plastics, Marley Pipe Systems and Fiberpipe have been confirmed as four main sponsors of this annual conference that attracts local and international experts involved in the manufacturing, installation and specification of plastic pipes, as well as the development of pipelines around the world.

Economist and author of the bestselling book, “The Long View”, JP Landman, has been invited as keynote speaker and will offer delegates a brief analysis of South Africa’s current and expected political-economic landscape, focusing on trends in politics, economics, demography and social capital.

According to Venter, the organising committee is currently in the process of finalising the line-up of speakers for this year’s conference, and they are still expecting last minute submissions from presenters.

Topics of presentations will range from plastic pipe failures, field pressure testing and pipe fittings to infrastructure, modelling of operating conditions for gravity and low pressure pipelines with factory tests.

The programme includes the following local and international presenters:

Economist and author of the bestselling book, “The Long View”, JP Landman, has been invited as keynote speaker at this year’s Pipes VIII conference

High scoring affair in KZN Everyone’s a winner on the day

ASSOCIATION NEWS

BY GARTH TAYLOR

The Plastichem ladies team – comprising Janine Santo, Angela Taylor, Nicolle Williamson and Roanne Scott – performed admirably, finishing with an impressive score of 106

A BIG field of 144 players turned out this year for the PISA KZN golf points. Old age is catching up. day in Durban. The fourball from Skyland SAPY Colours came to the fore, Masterbatch, our main sponsor, teed off first sponsoring a magnum of wine for and the day was on and, from the scores every player. A big thank you to Dr returned, it looked like all had a good time.

Majid Zarrebini and Tracy. Aeromarine The sponsors of the holes all threw their sponsored the caps which were top quality. weight into the event and provided ‘nectar of Each and every player gets a prize in the fruit’ to soothe the nerves of those playing the KZN golf day, so all went home very badly. There were also some very nice ladies satisfied. out on the course to encourage the players.

On behalf of PISA KZN, big thanks The halfway house, sponsored by GPS to all the sponsors for the day: main Plastics, was a hive of activity as, due to sponsor Skyland Masterbatch; Plastichem the large field, there was a wait of about 30 for their generous sponsorship; and minutes at the spot – so a few brown bottles SAPY Colours; and Aeromarine, which were consumed. At the end of the day all sponsored the top quality caps. finished in the light and the scores were high.

Hole sponsors were Megapak, The two President Plastics fourballs Plastichem, Hosaf, Khulunathi Electrical, were the winners and runners-up on the Lovemore Bros, Continental Compounders, day with impressive scores of 113 and 112.

Workforce Placements and GPS Plastics.

Congratulations to the Newcastle company.

We must note that one of the President The Plastichem fourball included Chris Kortenhoven, Plastics ‘A’ team players was just 11 Nip Lennon, Helmut Oellermann and Edwin Delport years old! Watch out for Thaveshan Govender in the future – he scored 31 points for his team, but could not even carry the trophy!

The Natal ‘country districts’ teams were really strong on the day, with the fourball of Boxmore of Harrismith ending third with a score of 111.

The longest day went to the PISA national vice-chairman Garth Taylor with a mere 13

Winners – The winning team at the PISA KZN 2014 golf day was the President Plastics 1 team, including Shiven Govender, Dhevan Govender and Thaveshan Govender (fourth player Leon Naicker missed the prizegiving), with the KZN champions’ trophy, the impressive rhino sculpture. Here we see the team – who scored a whopping 113 points! – with Tsepiso Lekitlane of Hosaf, a member of the KZN committee and the team’s sponsor, Bobby Pillay of BNR Agencies The second-placed President Plastics II team, who ran up 112 points, included Paul Mogo, Dave Govender and Rennie Govender.

Their fourth player was Douglas Slowgrove

Luck of the draw as rain stops, just in time

48

AUGUST / SEPTEMBER 2014

Otherwise we’d have spent the day in the clubhouse THE PISA Western Cape branch’s 2014 golf day was played on a glorious winter’s day at the Durbanville Club. The days, if not weeks, prior to the event were characterized by rain, and lots of it, so it was a surprise and a relief when 2014 winners – The winning team from Specialised Plastics Industries were in fine form, just pipping their ‘second’ team to the post on the day, a commendable result.

Ronald Niebuurt, Derek Waar, Leroy Retief and Herman Kirschbaum received their deserved prizes from Tania Smit

Thursday 12 June dawned fine and clear. Here at the southern tip of Africa you don’t the weather for granted … in fact, you don’t take anything for granted!

The Cape event is usually played in March or April, but someone forgot to book the venue this year and we were shifted over to mid-winter. Still,

SPI ‘II’ – The Specialised Plastics Industries ‘second’ team finished in fading light and still outscored all but one of the teams, their SPI counterparts. Well done to Danie Maritz, Gareth Williams, Mark Pereth and Anthony Weinberg, who received their prizes from Tania

undeterred, a field of just over 80 contested the day, at which we were fortunate to have the materials suppliers Plastichem and Plastomark as sponsors.

Thanks are due also to the companies which sponsored or donated prizes, including Alplas, Gold Sun, Journeys End Winery, Plastichem, Plastomark, Progetto, Polyoak, Tuffy and West African Group.

The Plastibottle team – with Mark Stannius, Mike Smith, Tom Thomson and Ian Huddlestone – played good golf and finished third

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Icy wind doesn’t faze Northern’s big hitters Cold but clear … means you can see the ball but not play it THE PISA Northern golf day was shot out at Modderfontein Club on a Friday in early June and the temperature that day was no laughing matter – although it was clear, an icy wind from the Berg or somewhere cut through and gave most the shivers … but they build them tough up here and the Gauties were unfazed. In fact, several commented that it was PISA Northern’s best golf day in several if not many years.

Our new sponsor, Plastichem, was warmly welcomed on board and the whole day went off smoothly. Some guys even managed low scores (somehow they beat the cold). The other sponsors included Sasol,

PlastiColors, Banbury Chemicals, Logistics Transport Globally, Nissei ASB, Eastman, Bayer, Gundle and Plastomark. Thanks are due to all for making this a fun event where many old friendships were renewed … and well worth repeating.

The Nissei ASB team ‘A’ team was strong on the day, plus they attracted support from the ladies. Here we see Ewoud Basson, Leroy Thangamuthu, Corne Pretorius, Janine Krugell and Michelle Shanahan Garth Remmington finished in third place and received his prize from Debbie Beaton, who helped organise the event

Martie Becker of Schaldor Plastics was on fire as usual, finishing fourth overall and showing the men how to play the game

Best score – Grant Matthews received the PISA Floating Trophy from Debbie Beaton. The trophy goes to the PISA member with the best gross score on the day. Due to insurance concerns, the tropht cannot be taken home, but Grant did get a ‘take home; trophy sponsored by Graeme MacDonald of Echo Acrylic

Vinyl SA 2014 Conference

50

AUGUST / SEPTEMBER 2014

ASSOCIATION NEWS

Emphasis on continued development of PVC, meeting challenges of business, sustainability, inspiring innovation THE Southern African Vinyls Association (SAVA) will host the Vinyl SA 2014 Conference at the Sandton Hilton Hotel, Johannesburg, on Monday 22 October.

Vinyl SA 2014 will focus on presenting a full and varied programme of original papers covering all aspects of PVC, from formulation through to recovery and recycling. Approximately 14 papers from national and international speakers and over 150 delegates are expected from at least 10 countries.

Emphasis will be given to how PVC continues to develop, meeting the challenges of business and sustainability and aiming to inspire innovation across its vast applications!

Keynote speaker is Peter Willis, senior associate at the University of Cambridge Institute for Sustainability Leadership (CISL).

Peter is a facilitator, consultant and speaker on the leadership needed for a viable human future. From 2002 until July 2014 he was the South African Director of CISL and ran the annual South African senior executive seminar of the Prince of Wales’s Business & Sustainability Programme, something he continues to do. During that 12-year period he developed an extensive regional network of sustainability oriented leaders within the corporate sector and beyond.

Delegate costs are R1750 for non-SAVA members and R1100 for members. For more info or to register, visit http://gallery.mailchimp.com/7e094cb409d5c6d5fec9a9bb5/ files/b7aca230-f67f-44be-98f7-37861272f451.pdf www.savinyls.co.za

Composite springs for

Audi

AUDI AG is introducing suspension springs made of glass fibre-reinforced polymer for an upcoming upper-midsize model.

The Volkswagen AG subsidiary is collaborating with an undisclosed Italian supplier on the part, which will be in production before the end of the year, according to a company news release.

The spring is about 40% lighter than the steel alternative.

“The GFRP springs save weight at a crucial location in the chassis system. We

The glass fibre-reinforced polymer spring going into an Audi sedan later this year, left, is about 40% lighter than the more conventional steel spring

are therefore making driving more precise and enhancing vibrational comfort,” said Ulrich Hackenberg, a member of Audi AG’s Board of Management for Technical Development.

The spring is made by wrapping glass fibres in alternating angles around a core of twisted fibres impregnated with epoxy resin.

The completed fibre strand is thicker than the wire of a steel spring and the spring has a slightly larger diameter overall.

The automaker says it does not corrode and is impervious to chemicals.

Altuglas nanostructured sheet used on

52 AUGUST / SEPTEMBER 2014

winning superbike ALTUGLAS International’s ShieldUp acrylic elastomer sheet is being used on the Kawasaki superbike ridden to victory by Tom Sykes, 2013 superbike world champion at a race in Misano, Italy in June. The sheet is comprised of polymethylmethacrylate and elastomer organized as a nanostructured mesh to improve performance. Altuglas claims ShieldUp provides high impact resistance, transparency throughout temperature fluctuations and high chemical stability. The properties expand the potential uses of acrylic sheet into areas such as automotive, where Altuglas says it can replace glass, which is twice as heavy. The elastomer content of ShieldUp significantly boosts impact resistance compared with conventional acrylic sheet, says the Colombes, France, company. Nanostructure details are measured on the scale of a billionth of a metre.

www.altuglas.com/en/

The ‘Mason Jar’ reinvented!

THE Mason jar is back – reinvented as a plastic, insulated tumbler branded ‘Aladdin’ with a handle and plastic straw sticking through the stainless steel lid.

Made of SAN plastic, this mother-ofall-tumblers hits the market this summer as the thirst of ice-tea drinkers reaches its peak. It comes with a polypropylene lid and

smoothie-sized straw. Of course, the plastic is BPA-free!

Mason patented his jar in 1858, the threaded neck and screw-on lid sparking a home-canning revolution by making it safe and easy to preserve veg and fruit fresh from the garden. During its heyday from 1939 through 1949, more than 3 million Mason jars were sold.

Today, original Mason jars are prized collectibles and are also are inspiring a new generation of jars.

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Sidel designs

PET beer bottle PET beer bottle mimics glass SIDEL Group has launched what it calls the world’s first pasteuriseable lightweight PET beer bottle with a standard ‘champagne’ base – not a petaloid-shaped base with feet.

The bottle also accepts a crown closure, mirroring the closures found on glass bottles. The new bottle weighs just 28g, 86% lighter than glass beer bottles.

When packaging beer it is critical to prevent oxygen from entering and carbon dioxide from escaping. The Sidel bottle can use single-layer material blends and Sidel’s Actis gas-barrier technology which gives a six-month shelf life.

Sidel officials also are fighting back against what they say are misperceptions about beer in plastic, like the common

belief that beer gets warmer quicker.

Sidel’s studies show PET keeps beer just as cold, for the same amount of time, as glass.

The base is a key. “For many consumers, a petaloid base is associated with other product categories such as carbonated soft drinks or sparkling water, and therefore when it appears on a beer bottle it can negatively affect the brand perception,” said Christophe Bunel, head of packaging care at Sidel. “But increasingly, consumers are becoming more aware of the benefits of PET, because they experience it as the preferred packaging material of choice in other food and beverage areas in their

The new Sidel beer bottle has a ‘champagne’ base, as opposed to a petaloid-shaped base with feet

life. So to help producers and consumers alike make the transition we wanted a bottle that looks like glass, but has all the benefits of PET.” www.sidel.com

Innovative child resistant closure Child resistant closure mechanism contained in the cap assembly itself GLOBAL Closure Systems has launched ‘Hector’, its new standard Child Resistant Closure (CRC), a user-friendly and lightweight Angle Neck Bleach (ANB) Child Resistant Closure. This new 2-part ANB CRC assembly has a snap on neck finish to safely retain it to the container neck featuring a new CRC operating system developed by GCS. The total packs are accredited to latest IS0 8317:2003 standard, offering a good balance of safety for young children whilst allowing adults to easily and safely handle the product Unlike most of the ANB CRCs currently available on the household market, Hector’s CRC mechanism is contained within the cap assembly itself and not the normal combination of the cap and extrusion blow moulded container neck design.

This means all the accuracy of the CRC system is contained within two injection moulded parts leaving the bottle maker only needing to produce a snap on neck finish. The CRC system is a combination of cams moulded into the closure body and locating features within

the top cap design, which unlocks the CRC mechanism when squeezed by the consumer whilst unscrewing the top cap.

This new closure system allows consumers to clean in a much more convenient way thanks to its directional nozzle which is ideal for precise dosage.

What’s more, the system comprises a transparent cap which enables users to check at a glance whether the spout is clean. The versatility of the closure means that it can be used not only on brand new cleaning products but also on existing range.

Hector is suitable for PET, PP and PE bottles and is compatible with swan or standard neck finish.

It can be used in conjunction with a number of different product formulations including ammonia and bleach and for various cleaning applications such as glass, kitchen and bathroom surfaces and the toilet bowl. www.gcs.com AUGUST / SEPTEMBER 2014

53

DESIGN

Street Shark nabs JEC Americas Innovation Award The most innovative composite solutions worldwide device, and the airstream from the gripper determines A POLYURETHANE car hood from Frimo Group GmbH whether the granules within the cushion can move freely or has been awarded an Innovation Award in the automotive jam and solidify. This allows specific forming or draping of category at JEC Americas, the composites trade show in the textile into the mould, for RTM. Atlanta held from 13-15 May at the Georgia World The ballistics category winner went Congress Centre. The aptly named Street Shark to two French companies, PPE and hood has a textured finish which cuts wind Cedrem, for the BBOX high-energy resistance, as well as reduces weight. absorber for the defence market. The Frimo used skin from an actual shark to composite structure protects vehicles and design the aluminium mould for the part, buildings from detonation or flying debris from made by resin transfer moulding. Prototypes improvised explosive devices. It uses “oriented are used on special modified versions of two bridge” composites that absorb energy when the sports cars, the Porsche 911 and a BMW Z4. spacers rupture.

The special BWM Z4 has Street Shark on the The construction category went to three roof and hood. The Porsche, still in production, companies: Kompetenzzentrum Holz GmbH will have a hood with the material. of Austria, Johns Manville in Germany and The PU hood weighs about 1,8kg less than FunderMax GmbH of Austria. The part is a aluminium hoods used on those two cars. non-combustible composite panel for decorative Frimo used in-mould coating to manufacture Frimo used the facades. the hood. Polyurethane was moulded over a actual skin of a shark to The first ukulele made of natural fibre honeycomb structure, and because PU flows develop the pattern for its composites won the sports and leisure category well, it allowed the use of a smaller, lessaward-winning car hood award for Swiss materials company BComp and expensive moulding machine, with less pressure.

U.S. partners, Blackbird Guitars and Lingrove Composites.

Other JEC America winners Lingrove combined BComp’s low-crimp ampliTex-brand flax Street Shark was one of 10 JEC Innovation Awards with its cashew nutshell-based bioresin make a novel, highrecognized at the Atlanta show. performance pre-preg called Ekoa. The material combines low TSE Industries Industries won the raw materials weight, high strength and toughness with sold quality. category for bio-based EcoSpray 550 urethane reinforcing Owens Corning Corp, operating in France and the US, resins made from natural renewable oils, for spray layup. picked up the wind energy category award, for wind turbine Stäubli GmbH of Bayreuth, Germany, won the blades made for WINDnovation in Germany. Owens Corning reinforcements category prize for its double rapier weaving used its new Ultrablade unidirectional and multiaxial glass machine for the economical production of three-dimension reinforcement range of fabrics. The stiffness and strength of weaves, which can be locally adapted, to make reinforcing the new reinforcement were improved by more than 15%. fabrics. Unlike conventional weaving machines, two or more grippers can be used for the weft insertion, enhancing The first ukulele made of natural fibre composites netted the sports productivity. and leisure category award for Swiss materials company BComp and U.S. partners, Blackbird Guitars and Lingrove Composites. Lingrove Plataine Technologies (USA), won in the software category combined BComp’s low-crimp ampliTex-brand flax with its for its software that bridges the gap between computer aided cashew nutshell-based bio-resin make a novel, highdesign and enterprise resource planning. performance pre-preg called Ekoa. The material Germany-based aerospace company EADS was named combines low weight, high strength and toughness with sold the winner in processing category, for its novel fibre patch quality preform (FPP) process that combines a material supply unit, a pick-and-place robot and a tool manipulation robot.

The machine continuously manufactures fibre cuttings that are then picked, placed, draped and fixed on a preform tool, to create a dry-fibre preform.

Technical University of Braunschweig, Germany, won the automation category for its FormHand process. It uses a six-axis articulating robot that places the material on a preforming 54 AUGUST / SEPTEMBER 2014

www.jeccomposites.com

DESIGN

JEC Europe 2014

Champions of

All show technical interest, market potential, partnerships, financial & environmental impact, originality FIFTEEN companies and their partners received an award at JEC Europe in March for their composites innovations. The jury selected the best composite breakthroughs, based on their technical interest, market potential, partnerships, financial & environmental impact and originality. In 2014, the winners broach a wide expanse of domains from raw materials to design and processes and applications.

AUTOMOTIVE: Porsche (Germany), 918 Spyder: Innovative material and manufacturing approach for a multipart aerodynamic underbody This concept consists of an innovative, multi-part aerodynamic underbody (front, middle, first and second rear).

The challenge was to find a balance between cost and technical requirements and weight targets. The main requirement was to achieve optimum aerodynamic flow.

The underbody front section was processed by press moulding using a carbon SMC material. The underbody middle section was made from UD carbon prepregs, balsa wood and glass fibre prepregs, using a prepreg compression moulding process with a core steel mould. The first and second rear sections were made from carbon prepregs and a Rohacell core in a prepreg autoclave.

The entire load-bearing structure of the 918 Spyder is made of carbon-fibrereinforced polymer for extreme torsional rigidity. Additional crash elements at the front and rear absorb and reduce the energy of a collision. The car’s unladen weight is approximately 1 685 kg.

AIRCRAFT INTERIORS: Expliseat (France), the Titanium Seat The Titanium aircraft seat is the most efficient economyclass seat for the A320 and B737 families and is the first composite aircraft seat to pass dynamic 16g crash tests.

Its combination of a composite-titanium structure and simple assembly makes it the market’s top-performing seat.

The Titanium Seat was developed as a joint effort, using specific technologies such as RocTool’s latest 56 AUGUST / SEPTEMBER 2014

3iTech® technology, where inductor coils are directly integrated in a steel compression mould. Expliseat was also looking for a high-strength fibre that would be compatible with the specific thermoplastic resin system developed for the application and that would also be unsized. HexTow® AS4 12k is perfectly suitable for Tencate’s process and, in combination with the thermoplastic resin, it performed so well that it passed the most demanding tests for seat structures.

CONSUMER GOODS: Owens Corning (France), New reinforced thermoplastic composite for washing machine tubs Original equipment manufacturers of household appliances such as washing machines need innovative solutions to fulfil the consumers’ growing demand for better performing, more durable products. Current mineral- and glassfibre-reinforced PP materials did not meet stringent specifications which would allow for greater product improvements. This led Polyplastic to develop, together with

composites innovations Owens Corning, a new grade of glassfibre-reinforced PP with excellent polymer matrix adhesion, superior hydrolysis resistance and flowability, specifically for washing machine tubs.

This new application successfully underwent the stringent Accelerated Life Testing (ALT) trials and has been approved for series production. It has a huge potential in both Russia and Europe with around 15% of volume growth per year. The major benefits resulting from this project are a 30% increase in laundry load from 5kg to 7kg for the same washing machine model. The material also has excellent mechanical properties, allowing high-speed spinning up to 1,500rpm, and superior hydrolysis resistance that extends tub life.

OIL & GAS: Advanced Composite Structures Australia Pty Ltd. (Australia), Petronas (Malaysia), Novel Composite Clamps for Pipeline Repairs This innovation was developed as a repair system for pipes with leaking through-wall defects, to be used in the oil, gas and petrochemical (OG&P) industry. The clamp is comprised of two half shell sections with flanges, cylindrical in shape to conform to the pipe. During installation, the flanges are brought together and bolted in position to secure the repair. There is a small gap between the pipe and the inside of the composite clamp. The clamps currently available on the market are all metallic, making the composite stand-off clamp described here a world first. The composite standoff clamp has significant potential in the global market as a direct replacement of existing metallic clamps due to benefits such as lighter weight and corrosion resistance.

SUSTAINABILITY: DSM Composite Resins AG (Switzerland), New composite system for wind turbine blades Most of the material systems currently used in the manufacture of wind turbine blades are based on epoxy resins.

While providing fatigue resistance, these resins are difficult to process, sensitive to process variations and require a timeconsuming post-cure to reach optimum physical properties.

A new-to-the-world composite system is being evaluated by Siemens Wind Power for its next generation wind turbine blades. This system offers the best of both worlds: easy resin infusion and processing, zero styrene emissions, and excellent fibre/resin interaction yielding superior strength and fatigue resistance.

The system is based on DSM’s Beyone™ 201-A-01, a resin that is styrene-free, cobalt-free (based on BluCure™ Technology), and 40% bio-based. It also uses 3B’s novel SE3030 glass rovings.

Enhanced adhesion to the reinforcement is achieved through an optimized sizing applied on the glass filaments. The new composite system offers many benefits to wind turbine suppliers, including significantly reduced blade manufacturing costs and higher process output. The sizing ensures excellent fibre/ resin interaction, resulting in improved composite properties for long-lasting blade operation. In addition, it has been demonstrated that this system can be used to produce long blades

at a record speed (through faster resin infusion and limited post-cure), resulting in increased output per mould and an outlook for excellent process consistency.

Other JEC Europe winners were: DESIGN: Hutchinson (France), Composite Semi structural Cockpit Module for ATA 25 SIMULATION: University of Twente (Netherlands), Braiding simulation and optimization PROCESS: Fraunhofer IPT (Germany), “Multi-Material-Head” – New laser-assisted tape placement system for thermoset-tape-, thermoplastic-tape- and dry-fibreplacement AERONAUTICS: University of Applied Sciences Rapperswil, Institute for Material Science and Plastics Processing (Switzerland), Development of a composite annulus filler for Rolls-Royce jet engines CONSUMER ELECTRONICS: Motorola Mobility (USA), All-thermoplastic composite smartphone back covers MEDICAL: Groupe Médical Gaumond (Canada), Transportable hyperbaric chamber PRESSURE VESSELS: Maruhachi Co., LTD. (Japan), Ultra-durable CFRP highpressure hydrogen fuel storage tank WIND ENERGY: Saertex GmbH & Co. KG (Germany), New production process: ‘Mapretec technique’ RAILWAYS: ApAteCh-Applied Advanced Technology Company LTD (Russia), Composite hopper car body produced by vacuum infusion MARINE: North Thin Ply Technology (Switzerland), World’s Thinnest UDPrepreg and associated handling and design tools AUGUST / SEPTEMBER 2014 57

THE DESIGN FACTOR…

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

Compete against

DESIGN

imports – exploit THE dialog in a recent radio advert summed up the somewhat dormant status of the South African plastics product manufacturing industry. Some may have heard it and with a shrug of the shoulders dismissed it as just an advert for another product. But in fact it is an indictment of what we are not doing here.

The script for the advert went something along the lines of: Customer questions: “What are those plastic boxes for?”

Assistant answers “General storage, helps keep your workshop tidy.”

Customer response: “Just what I need, I’ll take four.”

Customer: “…and these?”

Assistant: “CD storage boxes, German import!”

Not just another product, but a product imported from Germany no less. Why is this? Is it that old cliché “if it’s imported it must be better”. Is it price? Is it quality?

Is it function? All can apply as criteria for purchase, in most cases price will be the prime influencing factor but at +/- R114 for a simple plastic box to hold 18 CD’s, it is not that cheap. Maybe there are some added features that can only be set at the door of good design.

The scenario played out in the advertisement turns into commercial reality when the satisfied customer

leaves the store R500 lighter but with a selection of plastic boxes the origin of which he has no real interest They are certainly not sourced from local manufacturers whose machines are underutilized and are nowhere close to working 24/7. Whereas China, Taiwan, Germany plus other exporters sit back and enjoy watching the money roll in.

Companies that succeed in exploiting export markets have a number of things in common; they recognise that design is everything, without it they accept that they would not have a competitive edge.

They have determined that design is the differentiator.

All business can benefit from design.

The benefit is greatest when design is intimately related to solving problems, especially customers’ problems. As a direct result of these operating principals their manufacturing sectors have been stimulated into action and growth.

Design-active companies are not only successfully exploiting export opportunities, they are also putting in place strategies that will

compete against product imports into their own markets. Locally produced products offer their own domestic customers a choice of quality, well designed, competitively price products.

South Africa’s design resource is being developed at a keen pace. The tertiary institutions in Johannesburg, Pretoria and Cape Town produce talented young designers that are eager to change the face and tempo of our product manufacturing base.

There is clear evidence that by adopting design led policies companies have secured a number of tangible benefits; firms have accelerated business growth and increased market share with the successful launch of new products and services. Additional spinoffs can be seen specific to brand penetration, plus

Snapp Design’s awardwinning ‘engage’ wine rack. The possibility of having a subtle impact on humanity through inspirational products was the motivation behind Jonathan Fundudis when he established snapp Design. Together with David Holgreaves their process of discovery is encouraged by the redefinition of products whilst remaining true to the brand ethos

The Designer Collection of taps and mixers from Cobra were crafted exclusively by Brian Steinhobel

58 AUGUST / SEPTEMBER 2014

South Africa’s design resource is being developed at a keen pace.

This lily chandelier is part of an award-winning sustainable lighting series ‘Other People’s Rubbish’

by South African designer Heath Nash

design significant social development with an increase in employment opportunities.

The very credible National Development Plan with all of its defined objectives that are to be achieved by 2030 makes no mention of “design or innovation or product development” – the fundamentals that need to be in place if we are to manufacture products that will sell. It is not just a need to challenge the levels of imports; it should be a principal objective to put in place initiatives that encourage industry to exploit design.

This encouragement could be in the form of subsidised design time, where the smaller industries within the SMME sector can access this design resource whose mandate will be to develop products that are appropriate to the manufacturing capability of the company: Products of quality, products that meet customer needs. Innovative products that deliver against market demands, both domestic and export, products that compete against imported products and win. Products that are made in South Africa.

Iconic furniture & interior designer Haldane Martin graduated in Industrial Design in 1992. In 1994 he began his own contemporary furniture design company in SA’s design capital, Cape Town.

His animated furniture designs such as the award-winning Zulu Mama chair have become much loved icons of a new South African cultural design identity.

The frames are made from rustproof, 60% recycled stainless steel.

The UV stable polypropylene plastic weaving material is available in various colours. The black coloured plastic is made from recycled factory waste

Designer Andy Cartwright said he looked past conventional design recipes and inspiration to focus on the consumer’s needs and idiosyncrasies to create Korol. Made of 100% recycled PP, Korol is a world-first and brings a fresh perspective to home décor. It uses geodesic mathematical formulas to create star-shaped components or “building blocks” that, when connected at their points, can form anything from tealight candle holders to lampshades and stools to enormous wall murals.

Brightly coloured silicone plugs add a sense of fun to the product and the options for what can be created are limitless.

Sutla combines creativity and engineering in world-class designs that are unique and functional.

Born out of the creative partnership of industrial designer, Altus van Zijl and aesthetic extraordinaire, Brigitte Hauptfleisch, Sutla specialises in furniture, product and interior design and all of their work is characterised by being sustainable and on-trend, made locally with careful attention to detail, boasting pop colours and clean lines.

AUGUST / SEPTEMBER 2014 59

MATERIALS

Plastic solution for geyser drain cock Lanxess’ Durethan DP BKV60 EF provides excellent surface finish WAM Metals (Pty) Ltd a brass, copper and aluminium component manufacturer has been investigating products that can be replaced with plastics due to the cost of non-ferrous metal and the ongoing theft of products manufactured from these metals.

WAM Metals have designed and developed a plastic drain cock for geysers which was previously manufactured from brass.

The plastic chosen was Lanxess’ Durethan DP BKV60 EF supplied by Plastichem. This is a 60% glass fibre reinforced polyamide 6 with extra flow properties that gives an excellent surface finish without any noticeable glass fibre visible on the surface.

Apart from the good surface finish, these high modulus grades are suitable to replace metals in certain applications.

Key properties of these grades are: ü High stiffness ü High mechanical strength ü Good processability ü Potential wall thickness reduction ü Suitable for replacing metals in structural components ü Improved design freedom compared to metals ü Faster cycle times compared to conventional thermoplastics

The product specialists at Plastichem were instrumental in assisting with the design of critical areas of the drain cock and a full Finite Element Analysis (FEA) on the product was performed to eliminate any costly modifications after the mould was made.

The drain cock has been tested by The South African Bureau of Standards to SABS 1808-53, and carries the SABS mark.

WAM Metals have a 712m2 plastic factory with 30 ton, 50 ton, 120 ton, 175 ton, 240 ton and 430 ton injection moulding machines.

• WAM METALS CAN BE CONTACTED AT 011 748 7428 www.wammetals.co.za www.plastichem.co.za

BASF commissions new flat laminating line for PU insulating panels BASF has commissioned a new pilot line at its Lemförde site for the development and discontinuous production of polyurethane insulating panels. The new flat laminating line facilitates the production of panels up to ten metres long using two different application techniques: Flat coating in which the material is applied into the open mould; and injection technology that optimally delivers the polyurethane into the closed mould using a novel mixing head.

Dr Andrea Eisenhardt, head of product development for PU rigid The new flat laminator for polyurethane insulating panels at the Lemförde site

60 AUGUST / SEPTEMBER 2014

foam, stresses: “At our testing centre, we can now implement a wide range of state-of-the-art projects and accurately replicate our customers’ production processes.”

Sandwich panels of PU rigid foam are used mainly in refrigeration, i.e. in refrigerated vehicles and containers, cold stores and other applications for which discontinuous panel production makes most sense.

The Elastopor® and Elastopir® PU system brands are specifically available to BASF customers for these applications. www.basf.com

At BASF, we create chemistry.

Enquiries: BASF South Africa Delyce Ririe delyce.ririe@basf.com Tel 011 203 2537 www.basf.co.za

MATERIALS

Industry-first transparent conductive PC film Designed to provide ‘next generation’ functionality WITH smart materials being one of the fastest growing areas of materials technology, SABIC and Cima NanoTech, a Singapore and US-based company, are together developing a plastics industry first: a transparent conductive polycarbonate film that has the potential to revolutionize the materials used in consumer electronics, household goods, automotive, architecture and healthcare.

The new material, designed to provide ‘next generation’ functionality, has the potential to further enhance performance, enable new innovative applications and open doors for new product designs, Ernesto Occhiello, SABIC Executive Vice President, Technology and Innovation, explained. This could translate into faster response touch screens for consumer electronics, transparent “no-line” anti-fogging capabilities for automotive windows, better EMI shielding effectiveness for electronics, and transparent WiFi/Bluetooth antennas for mobile devices like smartphones, tablets, laptops

and all-in-one computers.

Aligned with SABIC’s focus to provide solutions that will solve industry challenges, SABIC engaged in a joint collaboration with Cima NanoTech in the latter half of 2013 to develop the promising new material, which will be available for customer trials later this year.

The collaboration, leveraging both Cima NanoTech’s proprietary SANTE® nanoparticle technology and SABIC’s worldrenowned LEXAN™ film, a polycarbonate material, has resulted in the development of a new series of transparent conductive materials that are lightweight with excellent transparency, outstanding conductivity and high flexibility. Cima NanoTech worked with SABIC’s world-class team of scientists to jointly develop materials that not only meet the requirements of existing industries, but also stretches the possibilities for exciting opportunities by breaking

boundaries faced with current materials.

SANTE technology, a patented selfassembling nanoparticle technology platform, stands alone in providing high transparency with ultra-low electrical resistance, which is ten times better than the incumbent indium tin oxide (ITO).

In addition to its ability to meet optical grade specifications for display and touch applications, SANTE nanoparticle technology is also more cost effective as coating is performed via a wet coating, roll-to-roll process versus sheet-to-sheet. The conductive SANTE network is also mechanically robust, thus allowing it to withstand flexing, stretching, torsion and tension for flexible applications. The substrate can also be thermoformed into various curved and 3D form factors.

www.sabic.com

Baerlocher introduces stabilizers for PVC coatings Stabilizers for PVC coatings protecting against microbiological degradation BAERLOCHER, a leading global producer of innovative additives for the plastics industry, has introduced innovative liquid mixed metal stabilizers for PVC coatings protecting against microbiological degradation. The new stabilizers named Baerostab UBZ 635 XLP RF and Baerostab UBZ 782 XLP RF trigger a chemical challenge associated with DCOIT* and thus enables the industry to manufacture PVC products that comply with the latest EU regulations on biocides.

Biocides are widely used for products as sunshades, truck tarpaulins and textile architecture to avoid product degradation by biological effects caused by fungus, mould and microorganisms. In textile coating, biocides are essential to prevent mould.

Mid 2012, a new EU regulation on biocidal products came into force which had 62 AUGUST / SEPTEMBER 2014

to be fully applied before the end of 2013.

As a consequence many of the previously used biocides have been eliminated and replaced with DCOIT. DCOIT, however, leads to an undesirable chemical reaction with the components of standard stabilizers, reducing their efficiency. The new liquid mixed metal stabilizers Baerlocher has developed are compatible with DCOIT, avoid this undesirable chemical reaction and therefore can be dosed in the same way as the previous systems. *DCOIT= dichloroctylthiazolinon

• SCINERGY IS THE AGENT FOR BAERLOCHER IN SOUTH AFRICA

www.baerlocher.com

MATERIALS

Clear Stream Custom Water Craft, a New Hampshire (USA) company dedicated to building and designing one of a kind wood core composite kayaks and canoes, used Entropy Resin SuperSap INF for the hull construction of this kayak. The SuperSap INF is a ‘very thin’ resin line that’s generally used for infusion. There is no post-curing required so it also works great for hand laminating, really penetrating the tight weave cloth

Aerontec now distributing

‘green’ epoxy resin systems Fast cycle times, excellent thixotropic, fibre wetting characteristics, adhesion ENTROPY Resins has appointed Aerontec as the sole distributor of its plant-based sustainable epoxy resin systems in South Africa.

Entropy Resins have developed a range of eco-friendly resin products under the SuperSap™ brand designed for a wide range of applications and manufacturing processes. The epoxy system boasts a 50% reduction in carbon footprint and can be used in applications such as hand layup, castings, pultrusion, pre-pregs, filament winding, compression moulding, RTM and vacuum infusion.

The SuperSap range of performance grade eco resins feature improved adhesion and elasticity and are adaptable to

a wide range of processes and applications. The resins’ biomass is sourced as a co-product or from waste streams of other industrial processes, which significantly reduces its carbon footprint.

Cape Town-based Aerontec, a supplier and distributor of composite materials and technology in South Africa, was started in February 2002. Situated in Claremont, Aerontec offers a door-to-door road service to anywhere in South Africa.

Aerontec have recently opened an office and warehouse in Jeffrey’s Bay in the Eastern Cape, run by Gitta and Arno Syfert. Tel: 042 940 0070, email: gitta@ aerontec.co.za, arno@aerontec.co.za

www.aerontec.co.za www.entropyresins.eu

New TPE-S moulding compounds for auto windows Exhibit better cost-performance than standard TPE-s A NEW series of styrenic thermoplastic elastomer (TPE-S) injection moulding compounds provides automotive manufacturers with processing and end use properties that are superior to those of TPE-S materials currently used for window encapsulation.

The Sarlink® ME-2600 Series includes

55-, 65-, and 75-Shore A compounds that have low specific gravities of 0.93 to 0.94.

These specific gravities are comparable to those of TPE-S grades now used in window encapsulation but lower than those of PVC and EPDM, which typically exceed 1.10. Compared to the existing TPE-S materials, the new Sarlink ME-2600 compounds provide higher flow, enhanced surface appearance, improved tensile properties, and greater stability upon heat aging and UV exposure.

Sarlink ME-2600 compounds are being evaluated for rear side window encapsulation uses in 2016 models to be built in 64 AUGUST / SEPTEMBER 2014

North America.

Based on proprietary styrene block copolymer (SBC) chemistry, the Sarlink ME-2600 compounds are one of several new series of TPE-S elastomers added to the Sarlink product range, which traditionally has consisted solely of thermoplastic vulcanizates (TPVs). Other TPE-S series include high-performance and generalpurpose extrusion compounds and injection moulding grades for exterior trim, interior components, active grille shutters, and under-hood parts. www.teknorapex.com

EQUIPMENT

Liquiform™ for one-step bottle forming & filling I-KTW-S, the innovation from ConPro GmbH! A new technology that is targeted to bring significant energy and cost savings, as well as other benefits, to liquid packaging producers worldwide is LiquiForm™, a breakthrough blow moulding and filling manufacturing technology which uses consumable, pressurized liquid instead of compressed air to form plastic containers. By combining the bottle forming and filling processes into one step, this game-changing technology eliminates numerous manufacturing steps, significantly reducing cost and waste.

“LiquiForm represents a significant opportunity for the consumer products industry by creating a step-change in efficiency and flexibility. By partnering with respected equipment manufacturers as well as international converters and leading Fast Moving Consumer Goods (FMCG) companies, we are set up to have the technology achieve its full potential,” said Ann O’Hara, LiquiForm president.

How it works The preform is placed in the mould and then the actual liquid is forced at high pressure into the preform, moulding it into the bottle shape. This results in a filled bottle, ready for capping and labelling.

The LiquiForm technology has been validated with a significant range of packaging substrates, products and conditions using the same LiquiForm machine for cold, ambient and hot-fill containers.

LiquiForm is the result of a joint venture originally established by Amcor, a multinational packaging leader, and Sidel, a global provider of PET solutions for liquid packaging. The LiquiForm Group has signed agreements with Yoshino Kogyosho, Japan’s largest plastic bottle manufacturer, to further develop the technology, and with Nestle Waters, one of the world’s leading bottle water companies, to acquire their intellectual property in this innovative technology. www.liquiformgroup.com AUGUST / SEPTEMBER 2014 65

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

MATERIALS

China’s growing rail industry turns to plastics Significant energy savings, pioneering interior design, greater safety, comfort for passengers IN THE face of a growing population and increased urbanization, railway system manufacturers are seeking materials that reduce energy consumption while also being environmentally friendly and safe. Bayer MaterialScience and China South Railway Nanjing Puzhen have joined forces to create a new interior design for low-floor trams.

To achieve their goal of having lightweight parts with greater energy efficiency, the railway manufacturer chose Bayer’s Bayblend and Makrolon polycarbonate sheets for its train components.

In particular, CSR Nanjing Puzheng was seeking a material offering leading-edge interior designs while at the same time maximizing passenger safety through its flame

retardance. Bayer’s polycarbonate sheets offer all of these characteristics, and are also available in appealing designs, colours, and surface structures. The sheets are used for the interior wall paneling of the trams. CSR Nanjing Puzhen also praised Bayer’s support at all project stages from material selection to manufacturing.

Bayer thermoplastic sheets are produced through processes that minimize emissions and environmental impact. This is thanks to the application of modern extrusion technologies that allow processes to create high-quality, lightweight, and yet still durable interior rail components in an environmentally conscious manner.

The properties of Bayer’s thermoplastic

Bayer MaterialScience and China South Railway Nanjing Puzhen have joined forces to create a new interior design for low-floor trams based on lightweight Bay-blend® and Makrolon® polycarbonate sheets

sheets provide excellent dimensional stability over a wide range of temperatures.

At the same time, their production cycle times are shortened with new processes, allowing for greater production volume of thermoformed components. Bayer thermoplastic sheets used by the rail industry have satisfied all flame and smoke safety requirements, making them an ideal choice for industrial applications. www.materialscience.bayer.com

Shield end rings and shield rings made from glass fibre reinforced plastic No shrinkage in the vapour phase drying

the basis of epoxy resins. As a glass fibre reinforced high-performance plastic Durostone EPX-M combines a high dimensional stability with an extreme strength, even at high operating temperatures.

designers in the design and calculation of the height of the wound coil in the transformer, as safe values can be expected.

Lower wall thicknesses possible With the insulating class H (180 °C) DurosNo shrinkage in the vapour phase drying tone EPX-M has an excellent compressive strength even at high temperatures. Also the Classic materials such as pressboard or laminated densified wood shrink during dry- production of Durostone EPX-M shield end ing in the vapour phase kiln. This shrinkage rings and shield rings in lower wall thickness is possible, since even for very thin must be taken into account beforehand wall thickness the material has very high in the dimensioning of the components strength. for the transformers. Thanks to the high dimensional stability components produced High homogeneous strength from Durostone EPX-M retain their original Röchling is initially manufacturing shield dimensions. This simplifies things for the end rings and shield rings from Durostone® EPX-M as a blank in one piece. In this way No shrinkage during vapour phase drying: Röchling is the first manufacturer of shield end rings and shield rings for oil-filled power transformers made from glass fibre reinforced plastic the components have a very high homoDurostone® EPX-M geneous strength. The exact processing is carried out by modern CNC machines according to customer’s preliminary drawings, so weak points in segment transitions are excluded.

Röchling is the first plastics processor to manufacture shield end rings and shield rings for oil-filled power transformers made from glass fibre reinforced resin-based materials. The rings offered under the brand name Durostone® EPX-M do not exhibit any shrinkage after the vapour phase drying and so allow designers to calculate the dimensioning with precise tolerances.

The rings are manufactured in a special winding process and consist of a glass fibre reinforcement and a resin matrix on

www.roechling.com

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Rolf Essig of HMR High Tech Machine Tools was on-hand to showcase his highly advanced 3D rapid prototyping scanners

Turning design into reality –

rapidly!

68 AUGUST / SEPTEMBER 2014

EQUIPMENT

Demaplastech ‘open days’ encourage growth of rapid prototyping technologies DEMAPLASTECH Rapid Prototyping, established in 2010 and a Stratasys certified partner, distributes and maintains Stratasys 3D printers which are world leaders in 3D printing technology.

The Northriding-based company now offer two rapid prototyping technologies from Stratasys, POLYJET (Objet 24, Objet 30, Eden and Connex printers) and FDM (Mojo, uPrint, Dimension and Fortus printers), a range of more than 25 machines.

Demaplastech’s Jacki Kleynhans explains that 3D printing allows users to perform ‘fit, form and function’ testing of parts prior to mass production, as well as making sample parts for customer approval. By identifying and thus eliminating design flaws early in the production development life cycle engineering costs, tooling costs and time to market are greatly reduced. 3D printing also increases creativity and design flexibility by allowing designers to have a working part in their hands within hours.

Over the past few months, Demaplastech has been hosting monthly ‘open days’ at their offices in Northriding, Johannesburg, to encourage the growth of this revolutionary technology.

HMR High Tech Machine Tools run by owner Rolf Essig is also present at the ‘open days’ to showcase his highly advanced 3D scanners. HMR was awarded the ‘strategic reseller status’ from CREAFORM3D Canada in April this year. The range of

handheld 3D scanners include the HandySCAN, a portable 3D scanner of metrology grade, as well as the GO!Scan, the fastest 3D scanner on the market. The two companies offer a perfect synergy of products for rapid prototyping customers.

Visit the Demaplastech website for more information of future ‘open days’ or email info@demaplastech.co.za. www.demaplastech.co.za

Jacki Kleynhans of Demaplastech discusses the finer points of 3D printing with interested visitors at an open day

Stratasys 3D printing helps create RoboCop STRATASYS 3D printing pri technology helped to produce the iconic RoboCop suit and helmet created by Hollywoo Hollywood special effects company, Legacy Effects, for the 2014 RoboCop film.

Using Stratasys’ high resolution Objet Connex multi-material 3D printing technology, Legacy Effects produced eve every aspect of the RoboCop suit from the helmet to the boots as master mould patterns. T These pieces were then moulded and cast into other materials to create variants of the suit depending on the requirements of each scene. Some versions of the suit use used in the movie were composed of as much as 90% actual Stratasys 3D print printed parts. One example being the visor, which forms part of the helmet on the black version of the RoboCop suit, which is 3D printed with Stratasys tr transparent (VeroClear) material.

www.stratasys.com

TEL: +27 (0) 11 462 2990

SOLUTION

MACHINERY (PTY) LTD

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

“One total solution for Injection Moulding”

Color and material combinations that make you say “Wow!”

Introducing the Objet500 Connex3 from Stratasys, the world’s only full-color and multi-material 3D printer. Select from incomparably brilliant and consistent colors, plus a full palette of transparent colors — the only 3D printer to offer such a wide array. And it’s the only 3D printer that prints flexible materials in a broad range of shore values. All with ultra-fine detail creating the most true-to-life modeling possible. Stratasys is the proven leader in multi-material 3D printing.

For whatever your mind can imagine, visit stratasys.com/Objet500 Connex3.

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TEL: +27 (0) 11 462 2990 FAX: +27 (0) 11 462 8229 e-mail: jacques@demaplastech.co.za

EQUIPMENT

3D printing explained Q&A WITH JACQUES KLEYNHANS, DEMAPLASTECH MD DEMAPLASTECHâ&#x20AC;&#x2122;s open days which introduce customers to the amazing world of 3D printing are well worth attending! SA Plastics, Composites and Rubber was at their 4th open day of the year to learn more and see what the hype is all about.

Jacques Kleynhans, Demaplastech director, answered our questions: SA Plastics mag: How did you get into 3D printing?

Jacques: In 2010 I looked at adding something new and exciting to our product range. We have many customers in the manufacturing space running our DEMAG injection moulding machines and I believed they could beneďŹ t from 3D printing technology. Initially I was going to offer 3D printing as a service but one thing led to another and we were appointed as Stratasys distributors.

SA Plastics mag: What exactly is 3d printing?

Jacques: 3D printing, also known as additive manufacturing, is a process of making physical products by successively adding very ďŹ ne layers of resin, plastic or even steel, on-top of one another.

SA Plastics mag: Sounds complicated, how does it work?

Jacques: Using CAD (computer aided design), a designer will design a part in 3D. This 3D design is then saved as an stl ďŹ le, think of an stl as a PDF, in other words, a simpliďŹ ed version of the original CAD ďŹ le. This stl ďŹ le is sent to the printer and the printer software then takes the part and dissects it into slices, anywhere from 16 to 254micron thick, depending on the type of printer. These slices are then deposited layer by layer on the printing plate and the physical object is built from the bottom upwards.

SA Plastics mag: Wow, so is it possible to build something like the Eiffel Tower with 3D printing?

Jacques: If you had a printer big enough, then for sure anything is possible, but typically the print envelope is from 203 x 150 x 150mm, like on the Uprint SE. There are also very large industrial machines like the OBJET 1000 that can print 1000 x 800 x 500mm size parts.

SA Plastics mag: Are you saying that 3D printing will replace injection moulding?

Jacques: Not quite. For very short runs where you may need only 50 or 100 parts in, letâ&#x20AC;&#x2122;s say ABS, or you just need one sample to show a customer, 3D printing is a viable alternative to injection moulding because you donâ&#x20AC;&#x2122;t need to build a tool.

We all know how long it takes to build a tool and what it costs and also what happens if you make an error in your design which only comes to light when you take those ďŹ rst shots. A redesign of the tool is both costly and time consuming which can negatively affect your time to market.

Imagine designing your part on the Monday in CAD and having your parts in your hand on Tuesday. You can quickly test the parts in real world applications and make a design change and reprint the parts on the same day. What would have taken you months to achieve you have done in a few days and at a fraction of the cost.

SA Plastics mag: Ok, so some parts are usable straight out of the printed which is great, what else can I use the printer parts for?

Jacques: 3D printing is also great for ďŹ t, form and function testing. For example, companies like Bosch and Garmin will print all the various parts of a component like a drill or a GPS device to see how the electronics, casings, battery, bearings etc all ďŹ t together to verify their design prior to mass manufacturing.

Automotive companies like BMW and Jaguar can print the entire dashboard which allows them to check the ďŹ t, form and function of their design months before they start tooling. Trek Bicycles will print out various parts of their bicycles to see how they ďŹ t and integrate together.

SA Plastics mag: Can I also print in colour?

Jacques: For sure. Our OBJET 500 CONNEX 3 can take coloured cartridges which allows us to print up to 46 colours in one single print job.

SA Plastics mag: If I already have a manufactured part and I want to re-engineer or change it, can I do this?

Jacques: For this we team with a company called HMR High Tech Machine Tools owned by Rolf Essig. Rolf has a range of 3D scanners that allow you to capture a part digitally. Once the part is captured it can be modiďŹ ed if needed or even a replica part printed on one of our printers.

SA Plastics mag: So can I use the parts that are printed?

Jacques: It depends on what you want to do with the part.

For example, we have a printer that can print an acrylic based rubber, so I could easily print a tyre, but I wouldnâ&#x20AC;&#x2122;t recommend driving to Durban on it because the printed part wonâ&#x20AC;&#x2122;t have the same mechanical properties as a real thermo moulded car tyre. But you could use the printed tyre ďŹ tted onto a real rim to test the tread pattern for water dispersion and assess the tyres performance in wet weather driving.

We also have printers that can print real ABS, PC, ULTEM and even NYLON and these printed parts can What is also amazing is that you can print the inserts for an be used in the real world injection moulding tool like in the pics above. The green parts and can substitute injection are 3d printed inserts and the blue spoons are what we injection moulded in PP on one of our DEMAG machines moulded parts.

70 AUGUST / SEPTEMBER 2014

SA Plastics mag: So what do these 3D printers cost?

Jacques: We represent Stratasys â&#x20AC;&#x201C; a range of professional machines which range in price from R140 000. There are 3D printers on the market for as little as R10 000, but donâ&#x20AC;&#x2122;t expect too much from these in terms of quality or performance as they are meant more for the hobbyist market.

SA Plastics mag: How can people

&

Jacques: We have open days in Johannesburg every month and we will also be at Propak Cape. Or you can visit our website. www.demaplastech.co.za

EQUIPMENT

â&#x20AC;&#x2DC;SmartPowerâ&#x20AC;&#x2122; from WittmannBattenfeld at Fakuma I-KTW-S, the innovation from ConPro GmbH! A NOVELTY in the injection moulding market, the new SmartPower system from Wittmann-Battenfeld will be on show for the ďŹ rst time at the Fakuma show in Fredriechshafen, Germany, from 14-18 October. Equipped with servo hydraulics as standard, the SmartPower is the youngest member of Wittmann-Battenfeldâ&#x20AC;&#x2122;s PowerSeries.

In a smart way, it combines the advantages of hydraulic machines with those of all-electric machines: energy efďŹ ciency, precision, user-friendliness, compact design, high speed, cleanness â&#x20AC;&#x201C; everything you could desire in a machine. Simply smart.

On the second SmartPower machine on display at Fakuma, a 120/350 unit, a penholder will be produced from LSR in a 4-cavity mould supplied by Elasmo Systems, Austria. The mould technology used allows moulded parts to be manufactured from liquid silicone without sprue, virtually free of ridges, without waste and fully automatically. Thanks to their special design, the penholders adhere automatically by suction to any smooth surface when a light pressure is applied.

The penholders are removed, deposited on a conveyor belt and ďŹ lled automatically by a W818T robot from Wittmann.

The Wittmann-Battenfeld machines are supplied by KR Plastics.

A polyamide connecting rod for a compressor will be manufactured with an 8-cavity mould supplied by Greiner Assistec of Austria, together with a WS80 servo sprue picker from Wittmann, will be produced on one of the SmartPower machines at Fakuma in October

www.wittmann-group.com AUGUST / SEPTEMBER 2014 71

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EQUIPMENT

Evolution ultra fusion Twin-screw technology demonstrates advantages in production of multi-layer blown film EVOLUTION ultra fusion, the first direct extrusion technology for the production of multi-layer blown films from Reifenhäuser Kiefel Extrusion, boosts productivity and energy efficiency, reduces production costs and improves film properties.

The Evolution Ultra Fusion technology processes raw materials

72 AUGUST / SEPTEMBER 2014

A typical line configuration of the innovative Evolution Ultra Fusion technology by Reifenhäuser Kiefel Extrusion

The REItruder twin-screw extruder in a blown film line boosts productivity and energy efficiency and enables the use of 50% of fillers, thanks to the direct extrusion

directly – without previous pre-drying and compounding. For this reason, the engineers came up with the concept of integrating a twin-screw extruder of the REItruder series directly in a blown film line. Compared with the processing of compounds and masterbatches, the direct extrusion technology can reduce the production costs for 3-layer blown films by more than 15%.

The technology shows its full savings potential particularly in the production of filled multi-layer films in which expensive raw materials like polyethylene are replaced in part with lower-priced fillers such as calcium carbonate.

The Evolution Ultra Fusion technology enables producers to process especially high filling amounts of up to 50%. This allows them to reduce their production

costs by about 20%.

In addition to cost savings, the high filling amounts have a positive effect on the film properties: Film strength and film stiffness are increased while elongation is reduced. Special properties can also be obtained with this technology, eg. those needed for the production of breathable films.

Together with an industry partner, Reifenhäuser Kiefel Extrusion is developing products for industrial use to bring the technology to the market. Examples of applications for the Evolution Ultra Fusion technology include: Packaging bags for flower soil and peat Compression bag film Breathable and non-breathable diaper backsheets Breathable film Bio film, for example PLA plus filler

www.reifenhauser-kiefel.com

GIDUE finalist for Global Awards for Innovation 2014 GIDUE has been nominated a finalist in the shortlist for the Label Industry Global Awards for Innovation 2014 for its powerful Digital Flexo Excellence™ project. Digital Flexo Excellence is a system of technologies developed to digitize and automate the workflow, set-up and running of a flexographic press for labels and packaging. Digital

Flexo Excellence presses deliver high productivity, cost reduction, flexibility and consistent quality with digital efficiency, repeatability and ease of operation. It also features faster change-over times, higher press up-time and minimum waste.

www.gidue.com

EQUIPMENT

Metal detectors prevent damage to recycling machines

PLASTIC EXTRUSION WELDERS

reliable

Focus on efficiency, profitability, the sustainability of recycling processes AUSTRIAN company Starlinger GmbH is a global market leaders in the field of machinery and process technology for woven plastic sacks. Since 1987 the company has manufactured and supplied recycling lines for plastics, and in 2002 established its recycling technology division. This division includes innovative machine solutions for the efficient recycling of a wide range of plastics including PE, PP, PA, PS, PET, and others.

Starlinger employs new recycling technologies and a well proven and established machinery concept and since the beginning this concept has included metal detectors from S+S Separation and Sorting Technology GmbH. Plastic shredding is the first step in the recycling process and at this stage since metal contamination can cause damage to downstream modules reliable metal detection is therefore indispensable. Consistent metal separation prior to shredding reduces malfunctions and increases the profitability of the recycling lines and for this purpose S+S DLS type detectors are used and are mounted over the conveyor system prior to the shredder.

DLS detectors will detect magnetic and non-magnetic contaminants even if they are embedded in the product and by removing contamination prior to the process reduce costs due to machine damage and production downtime, guarantee product quality, and protect against customer complaints. DLS metal detectors can offer a rapid return on investment.

DLS metal detectors offer many advantages: They prevent metals from reaching cutting machines and thus avoid wear and broken cutting tools. They reduce downtimes and maintenance costs, they improve the quality and value of the cut material, they reduce malfunctions and off-times in downstream processing machines, and they minimise quality defects and reject rates in recycled plastic materials.

versatile

compact

performance

www.sesotec.com

efficient

powerful AUGUST / SEPTEMBER 2014 73

S+S DLS type detectors are used and are mounted over the conveyor system prior to the shredder

(T) +27 11 849 9058

(F) +27 11 425 3322

SALES@PLASTIWELD.CO.ZA WWW.PLASTIWELD.CO.ZA 45 GOLDEN DRIVE - MOREHILL EXT 8 - BENONI - 1501

Installation and Fabrication Plastics Pipe Association

PLASTIC WELDING TECHNOLOGY

EQUIPMENT

SIPA covers Africa from Cape Town office Italian PET packaging line manufacturer also supplies moulds and filling systems SIPA, the Italian manufacturer of machinery for the entire PET packaging line, has been supporting its activities in Sub-Saharan Africa more closely through an office at the southern tip of the continent, in Cape Town, which has been operational since early 2013.

For more than 30 years SIPA has specialized in complete manufacturing lines for PET containers, including design, production, filling and packaging solutions. SIPA tailors technology recommendations to customer needs based on unmatched knowledge and experience of the entire PET process. Headquartered in Italy, SIPA operates branch offices worldwide for fast access to service, parts and expert engineering support.

SIPA now operates 18 offices around the world. The branch office in South Africa was set up to better serve its customers both for sales and afters-sales service.

SIPA has worked for many years with major packaging suppliers in South Africa. It supplies packaging machines for preform injection, blow moulding and filling.

SIPA considers packaging development to be of primary importance and a major factor in products’ success: functional and innovatively shaped bottles with material weight reduction, optimised packaging performance and process stability are crucial in today’s bottle market.

Bottle samples are produced on 17 pilot machines where bottle performance is tested before being launched in the market.

Moulds are another significant element in SIPA’s product range. It has made huge investments in its tooling department, which has a production capacity of 5 000 blow cavities and 10 000 injection stacks a year. It produces complete injection moulds for the production of PET preforms, injection components and blow moulds.

SIPA has seen an increase in demand for its systems all over Sub-Saharan Africa since the establishment of the local office, which includes two staffers plus technicians for technical interventions at customer plants across Africa.

SIPA’S Cape Town office, tel. +27 21 418 2750, sipa. southafrica@zoppas.com The team at SIPA’s new South Africa office includes regional manager, Giovanni de Rosa, and communications manager, Martina Bottarel. Giovanni is involved in the servicing and after-sales support of existing as well as new SIPA systems users in the entire Southern African region, including East and West Africa 74 AUGUST / SEPTEMBER 2014

SIPA installs line for Cambodia’s first natural mineral water bottler Line produces bottles in 300, 500, and 1500ml formats CAMBODIA may have a monsoon climate, but you would be welladvised to avoid some bottled water there. Happily, things are changing, and SIPA is helping to make it happen.

A few years ago, Frenchman Bernard Forey discovered that a lot of bottled water in Cambodia was unfit for human consumption.

A while earlier, while in Vietnam, he had discovered a deep aquifer containing water with well-balanced mineralisation, similar to leading French brands, in the country’s Long An province. That aquifer became the source of La Vie mineral water, sold by a company that Forey set up and later sold to what is now Nestlé Waters.

He found a deep aquifer with the purest natural mineral water in South East Asia, put up a factory to bottle directly from the aquifer and then asked SIPA to propose a complete mineral water PET bottling plant solution.

SIPA supplied its own SFL 6/6 linear stretch-blow moulding unit, integrated with a complete set of downstream bottling and packaging equipment sourced locally.

The line produces bottles in 300, 500, and 1500ml formats. SIPA and Kulara Water are now working together to develop new designs for premium and lightweight bottles too.

Forey is NOW busy with studies for production of PET bottle preforms in neighbouring Myanmar. Discussions with SIPA to supply a production system for that future operation are well advanced.

AUGUST / SEPTEMBER 2014

75

www.sipa.it

To cut a long story short, Forey and his pilot son did an aerial survey of Cambodia over the Angkor temples and the mountainous region of Kulen, birth place of the Khmer civilisation.

He spotted an unexpected waterfall close to the top of Mount Kulen, as well as several rivers ďŹ&#x201A;owing to the plain of Angkor.

He bought 9 hectares of land at the foot of Mount Kulen and decided to drill there.

EQUIPMENT

Hi-Q Shaping – injection embossing further developed Possible to produce parts with constant weight, minimal shrinkage, excellent surface quality, low level of orientation and internal tension

BY MARTIN PHILIPP-PICHLER, PRODUCT MANAGER MICROPOWER, WITTMANN BATTENFELD GMBH DUE to its complete automation, high reproduction accuracy and minimal need for downstream finishing of moulded parts, injection moulding ranks among the most important manufacturing processes in plastics processing, and serves as the basis for many specialized variants of this technology.

But particularly strong directional orientation must normally be expected in injection-moulded parts, since in this process shaping is accompanied by major deformation, high deformation speeds and high-speed cooling; consequently, some of the molecules solidify with an orientation in the direction of the deformation.

This leads to significant anisotropy in the attributes of injectionmoulded parts.

However, components with attributes as isotropic as possible are increasingly required, in order to achieve the best possible surface quality and highest accuracy in shape and dimensions on the one hand and on the other hand to keep warpage, internal tension and orientation at a low level. Optical parts are particularly sensitive to anisotropy, since internal tension and orientation strongly diminish the optical brilliance due to the effect of birefringence.

Injection embossing – low material shearing and orientation This can only be remedied by applying a special form of injection moulding, i.e. injection embossing.

In this special process, the plastic melt is injected into a mould with a pre-defined embossing gap, then shaped by means of a pre-set compression stroke of the mould halves. Here, two different processes are in common use: complete filling of the cavity partial filling of the cavity Due to the high cooling speed inside the mould, injection embossing of thin-walled components and micro parts is largely restricted to the process with complete filling of the cavity. A compression stroke with partial cavity filling and an already frozen melt front would lead to surface defects and to the internal tension and orientation which should actually be prevented.

Injection embossing is characterized above all by low material shearing and orientation. As the holding pressure is not applied via the gating, but becomes effective across the entire projected surface of the component, this leads to a reduction in sink marks.

76 AUGUST / SEPTEMBER 2014

An improved venting effect due to injection into the open cavity can also be observed. Of course this requires a higher amount of capital investment in custom-built moulds and a specially adapted process control system.

The decisive processing step in injection embossing is primarily the application of the compression stroke. In conventional embossing processes, this stroke is time- or path-controlled, which leads to relatively low precision of the entire process in the area of micro parts, since time and path settings only allow a rigid process without information feedback from the moulded part.

Information about the thermodynamic states of the material inside the cavity and information feedback from the mould would make it possible to use a process specially adapted to the material processed. In this way, adjustments can be made to the specific behaviour of each material during the embossing phase in order to ensure a dynamic, flexible and material-preserving process.

Development of Hi-Q Shaping at Wittmann Battenfeld The micro injection moulding department of Wittmann Battenfeld has been engaged in developing such a dynamic injection embossing process for some time, in order to provide the improvement in quality demanded by the market. Thanks to its flexibility, reproduction accuracy and dynamism, the MicroPower machine model serves as an ideal platform for studies and tests in this field (Fig. 1).

Fig. 1: The MicroPower – ideal for a dynamic injection embossing process

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dean@relloy.co.za

EQUIPMENT The main goal of this latest development is to implement an extremely rapid, optimized injection-embossing process, to establish low-cost mass production of parts with nano-structured surfaces and improved material attributes.

With these objectives in view, Hi-Q Shaping was developed at Wittmann Battenfeld under the FP7 EU research program “Cotech” in cooperation with Microsystems UK, the Karlsruhe Institute of Technology KIT, the University of Bradford, the Technical University of Denmark DTU and the Department of Microsystems Engineering IMTEK at the University of Freiburg.

For this purpose, a new software was created and adapted to the MicroPower injection moulding machine.

Hi-Q Shaping by Wittmann Battenfeld is a process in which, similar to conventional injection embossing, the active movement of the clamping unit during the injection process plays a major part. In this innovative process, the reference input variable or reference value is extended by adding temperature and pressure values, which enables specific regulation of the embossing pressure (holding pressure) for every process via the closing stroke (Fig. 2).

Thanks to its extremely rigid toggle design, which is free of play but still permits high precision, the MicroPower is able to perform extremely accurate movements of the clamping plates and consequently precise compression strokes. Where micro structures are involved, the precision of the clamping stroke has an enormous influence on the pressure behaviour inside the part.

Due to the lower volume and small surfaces, the temperature conditions are much more critical than for larger parts. This is a highly dynamic embossing process which can only be implemented with adequate software, control technology and machine performance.

Flashlight lenses as trial specimens In the tests, flashlight lenses were used as trial specimens since these require high quality standards for the optical attributes and surface properties of the moulded parts (Fig. 3). These lenses

Fig. 3

Fig. 2: B6 program page for extended injection embossing and relevant evaluation

The aim is to apply the embossing pressure to the entire surface of the part above the glass transition temperature with a high degree of dynamism and precision. In this way, a drastic reduction in material tension becomes possible, since the deformation proceeds at significantly lower shear speeds.

High dynamism combined with ultimate precision is necessary, because micro parts solidify much faster than larger parts due to their small size/thickness, which reduces the time window for the compression stroke to a fraction. Therefore the viscosity of the melt is automatically taken into account at every stage.

Trial specimen flashlight lens

were manufactured from the polymer Makrolon LED 2045, a polycarbonate with extremely high light transmission.

Besides the PVT phase diagram, the effective temperature conductivity and the glass transition temperature must be considered as additional important material parameters, since they make it possible to calculate the actual melt temperature at any point in time and thus make the process controllable in the first place. Specification of the final part dimensions and the desired density is also required.

Birefringence effects were used to obtain information about internal tensions and orientations. Birefringence designates the proneness of optically anisotropic media to split a light beam into two beams polarized perpendicular to each other. A birefringent material is identified, for example, by using a polarization microscope. When the specimen is rotated between crossed polarization filters, the light intensity and/or colour of a birefringent object will change, while optically isotropic materials show no change in their appearance (Fig. 4).

Fig. 4: Internal tension and orientation made visible with polarization filters 78 AUGUST / SEPTEMBER 2014

Conclusions about the surface quality of parts produced can be drawn by using comparative light microscopy.

system for any comparable parts quality is necessary. Use of the injection embossing process generally leads to an improvement of both optical attributes and surface quality.

Wittmann Battenfeld is represented in SA by KR Plastics, email: keith@krplastics.co.za

Summary of results This new, innovative process makes it possible to produce parts with a constant weight, minimal shrinkage, excellent surface quality and a low level of orientation and internal tension. The www.wittmann-group.com following main factors influencing the quality of the moulded parts have been established: mould temperature compression force compression time The tests have revealed that this process yields a higher degree of precision than standard embossing.

Moreover, it was possible to reduce the internal tension and thus to achieve a significant improvement STANDARD HI-Q SHAPING in translucency (Fig. 5).

Moreover, the cycle times in Hi-Q Shaping are virtually on a par with those in conventional injection moulding and consequently ten times as fast as those in similar variothermic processes. This fact makes the process extremely economical and energy-efficient, as no high capital investment in Fig. 5: Birefringence effects and microscope photographs in standard injection embossing and Hi-Q Shaping a complex heating and cooling AUGUST / SEPTEMBER 2014

79

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

Taghleef Industries BOPP plant in Dubai

BOPP in the Middle East 8% of world’s BOPP supplied from Middle East to Europe, North Amer

80 AUGUST / SEPTEMBER 2014

FEATURE

BY DR NIALL MARSHALL

SINCE the 1980’s the oil- and gasrich countries of the Middle East have looked to diversify from being crude-oilreliant economies to economies based on higher value products produced from these raw materials.

The first petrochemical plants were built to produce important, but basic, industrial chemicals such as ethylene, methanol and benzene. The next stage of development was to start manufacturing more diversified petrochemicals using these feedstocks, products such as polyethylene and polypropylene.

In addition to further investments in petrochemicals and polymer production, the focus today is on developing and attracting investment in plastics converting. This is not only because of the additional value which can be captured, but also for job creation.

It is estimated that the value of petrochemicals to the economies is three to four times more than the crude oil and further value is added by further processing of those products.

ica, Africa, Asia

BOPP market expected to grow at 6% with a combined capacity of more than per year 500 000 tons per year and plans have To meet the twin objectives of adding been announced for further expansions value and creating jobs any potential in the next two to three years. products should be easily and cheaply The largest of these BOPP companies, shipped to large and growing export Taghleef Industries, headquartered in markets. It also helps if there is a Dubai, has grown by investment and strong regional demand for the product. acquisition to be one of the largest Bi-axially orientated polypropylene BOPP producers in the world with (BOPP) film, which is widely used in a capacity of over 400 000 tons per packaging, seems to year and plants in nine perfectly meet these countries.

The focus today requirements: there In the Middle East is on developing are more than 10 most of the capacity companies producing has been installed and and attracting polypropylene in the commissioned in the investment in region and the global last five years and so plastics converting. demand for BOPP film the plants are modern, has more than tripled versatile and big. Many since 2000 to over 7 million tons per of the lines are producing 8.7m wide year. Even in the current global slowrolls of 20 micron film at speeds of over down the BOPP market is expected to 500m/min and so require well stabilized grow at 6% per year. Unsurprisingly grades of polypropylene with very then there are a number of large BOPP consistent processing behaviour. producers in the region!

The latest BOPP production Historically, most BOPP was technologies are able to produce a wide produced in North America and Europe. range of films including transparent, However, in the last 15 years there has metalized, opaque or white, one- or been a strong shift to the Middle East both sides heat sealable, printable or and Asia. This has been driven by the different combinations of properties strong regional demand for BOPP in are available, in different widths.

Asia as a result of growing urbanization Today almost 8% of the world’s BOPP and opportunities to produce BOPP is supplied from the Middle East to in the Middle East for export with the customers in Europe, North America, increased availability of local PP. Africa and Asia.

And so it would seem BOPP Plans for further expansion of Middle production in the Middle East East BOPP production is a success – it adds value to The first BOPP plant in the Middle polypropylene and is easily exported.

East was established in Saudi Arabia The only problem is, as with most in 1989, mostly supplying film to local modern large manufacturing plants, it customers. In the last 14 years doesn’t create all that many jobs. another six plants have been established in the Middle East NIALL CAN BE REACHED AT: NIALL. Saudi Arabian Lays crisps – South MARSHALL@EVERSPRINGME.COM African cheese flavour

WORLD NEWS

Sealing the deal for Hong Kong-ZhuhaiMacau Bridge WATER tightness is key to the island and tunnel project of the Hong Kong-ZhuhaiMacau (HKZM) bridge. Trelleborg will ensure that 33 tunnel sections remain safe at deep-sea depths of up to 40m.

Since the official start of the island and tunnel project of the bridge in 2009, work has not stopped for engineers and other staff. Zhuhai, in Guangdong province, China, stands on the west bank of Pearl River Delta which feeds into the South China Sea. It borders Macau and faces Hong Kong on the other side of the delta.

As a combination of bridge, tunnel and artificial island, the 49.9km HZMB is a mega-link between Hong Kong, Zhuhai and Macau. The island and

tunnel project is a critical part of the overall construction work, and involves some of the most difficult to construct immersed tunnel in the world – and two artificial islands.

The project has been divided into four phases. The two artificial islands were built during the first phase. The second phase involved the construction and installation of the first tunnel section, which was completed in May 2013. The third phase involves installing the remaining 32 tunnel sections. This will be the most difficult and time-consuming phase, and will take around three years. The fourth phase will involve engineering

work inside the tunnel, as well as some construction work on the artificial islands.

The first two tunnel sections have been installed – 112.5m in length and weighing 50,000 tons each.

The expected service life of the

Empty Coke bottles become a COCA-Cola has teamed with 3D Systems Corp and its chief creative director, the musician Will.i.am, to develop a 3-D printing system that uses PET from recycled Coke bottles. The companies introduced the Ekocycle Cube during the Licensing Expo in Las Vegas, and said the Ekocycle will come with 25 ready to print concepts selected by Will.i.am, including smart phone covers, bracelets, vases and a birdhouse. The companies did not say how much of the material used by the Ekocycle will come from 20-ounce Coke bottles, but 3D Systems of Rock Hill expects this to be just the start.

phone case

www.3dsystems.com

82 AUGUST / SEPTEMBER 2014

Trelleborg’s seal makes sure the tunnel remains watertight

HZMB is 120 years, and it’s designed to withstand a magnitude-8 earthquake.

As a result, the tunnel sections need to remain watertight for 120 years.

Trelleborg won the bid for the job,

becoming the sole supplier of sealing solutions for the immersed tunnel.

The products ordered included Gina gaskets, Omega seals, waterstops and a variety of sealing accessories.

Toyota to launch hydrogen fuel cell sedan

www.trelleborg.com

Home-brewing is possible with plastics THE craft beer movement is creating new interest in home brewing, which is driving sales of introductory beer making kits complete with PET brewing equipment designed to make it easy for anyone to start brewing their own beer!

USA company, The Beer Machine’s starter kit comes with a two-gallon PET container that houses the beer during fermentation and chilling. It has integrated temperature and pressure monitors to keep track of the fermentation process.

There’s also a tap to serve the beer once it’s ready.

The Beer Machine used to have its own in-house injection moulding, with five presses ranging in size from 95tons to 320tons, and the company was among the first to use PET in large scale injection moulding, rather than in pre-forms and blow moulding. In addition to the PET barrel, The Beer Machine uses nylon for slide-on clamps and a cup and cap to house the pressure control valve. The valve itself uses a thermoplastic elastomer. The top cap, base and internal float are all made from polypropylene.

83

Makers of The Beer Machine use PET, PP, nylon and TPE in the home brewing kit

AUGUST / SEPTEMBER 2014

TOYOTA has revealed the final design for its new fuel-cell powered sedan. The car may blend concept car cues with Japanese global design blandness, but the fuel cell sedan is significant as much for the numbers involved as the futuristic look. Toyota confirmed this car will be launched by April 2015 in Japan and in summer 2015 in Europe and the US. Fuel cells use plastics extensively in the cells, the electronic connectors and the hydrogen storage tank. The fuel cell sedan was first shown as a concept car at the 2013 Tokyo motor show. It’s telling that Toyota will initially launch the sedan only in areas of Japan which support hydrogen refuelling. Today, there’s only a single public hydrogen refuelling centre in the UK near London’s Heathrow airport. By late last year, there were only 10 public hydrogen fuelling stations in the US. Refuelling takes three minutes, says Toyota, and it claims performance and driving characteristics comparable to a petrol-engined saloon of the same size.

Once a tunnel section is connected to the tunnel’s next tunnel seal, the partition wall is removed

AROUND THE WORLD EU sets strict limit for BPA in toys IN ITS continuous strive to improve the safety of toys, the European Commission has set a strict limit of 0.1mg/l (migration limit) of BPA in toys for children up to the age of three years and in any toys intended to be placed in the mouth. The limit was taken from European Standard EN 71-9:2005+A1:2007, which is applied voluntarily by the European toy industry to control the content of BPA in toys.

This has contributed to keeping the exposure of children to BPA from toys low in comparison to other non-food contributors such as cosmetics or dust, and far lower than the exposure from BPA in the diet according to the related report of the European Food Safety Agency (EFSA).

BASF evaluates natural gas-based investment in USA BASF is evaluating an investment in a world-scale methane-to-propylene complex on the U.S. Gulf Coast. The on-purpose production of propylene to supply the companyâ&#x20AC;&#x2122;s North American operations would allow BASF to take advantage of low gas prices due to U.S. shale gas production and considerably improve its cost position.

This would be BASFâ&#x20AC;&#x2122;s largest singleplant investment to date.

BASF intends to further strengthen its backward integration into propylene and grow its propylene-based downstream activities, leading to a stronger market position in North America. www.basf.com

European Union

ban for recyclables THE European Commission has announced that it has adopted proposals, including a landďŹ ll ban for recyclable materials, to turn Europe into a more circular economy and boost recycling.

The new waste targets for European Union members call for 70 percent of municipal waste and 80 percent of packaging waste to be recycled by 2030, and the ban of burying recyclable waste in landďŹ lls starting in 2025. Also included was a proposal for the reduction of marine litter.

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WORLD NEWS

New rubber production line opens in Dormagen

www.baypren.com

Site manager Ralf Tappe explains the new production line to board member Werner Breuers and business unit head Jan Paul de Vries. With a workforce of around 1000, Dormagen is the third largest Lanxess production site in Germany and one of the most important sites for synthetic rubber worldwide. The Baypren facility alone, which belongs to Lanxessâ&#x20AC;&#x2122; High Performance Elastomers (HPE) business unit, employs some 250 staff. HPE is part of Lanxessâ&#x20AC;&#x2122; Performance Polymers segment, which recorded sales of â&#x201A;Ź4.5 billion in 2013

LANXESS has completed the expansion of its Baypren polychloroprene solid rubber production operations in Dormagen.

The new production line uses the innovative dry ďŹ nishing production technology developed, tested and taken to the market-ready stage by Lanxess speciďŹ cally for this purpose.

This technology enables Baypren to be manufactured in a more resourcefriendly way. Lanxess is also adding two new variants of this high-performance synthetic rubber to its product portfolio at the Dormagen site. The company has

invested some â&#x201A;Ź18 million in expanding production.

The innovative dry ďŹ nishing technology reduces the number of production steps and conserves resources when manufacturing the synthetic rubber, among other things by dehydrating the rubber in a special extrusion device. This means far less water is required, which also reduces the amount of wastewater generated. The natural gas previously needed to dry the rubber is no longer necessary either, so less waste air is produced.

Bioplastic toys!

First and only brand to test and certify 100% bio-based product claim HONG Kong-based product development ďŹ rm Bioserie has launched what it says is the worldâ&#x20AC;&#x2122;s ďŹ rst line of infant toys made entirely from plant-based polylactic acid and additives.

The company said it focused its R&D on improving the heat resistance and durability of its materials, spending over three years researching and experimenting with bioplastics and developing its own manufacturing

technology for injection moulding using a special blend of the best available bioplastic materials. The company subcontracts its manufacturing to plastics ďŹ rms in southern China.

Bioserie launched sales of its teethers, rattles, stack toys and toy cutlery in May on website indiegogo.com. The company hopes to sell them more broadly with toy retailers and websites later in the year.

Recently some companies have introduced toys that are made of recycled plastics or a mixture of bioplastics and oil based plastics.

Bioserie will be the ďŹ rst and the only brand to test and certify the 100% bio-based product claim. www.bioserie.com

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WORLD NEWS

Swedish solar energy expert

for

CIGS solar cells

Increased efďŹ ciency of solar cells from 15% to 16.2% MIDSUMMER, a leading supplier of production lines for cost effective manufacturing of ďŹ&#x201A;exible thin ďŹ lm CIGS solar cells, has increased the efďŹ ciency of its solar cells from 15% to 16.2% aperture area of the full 156Ă&#x2014;156 mm solar cell. This increased energy efďŹ ciency further strengthens the business case and attractiveness of thin ďŹ lm CIGS solar cells.

The solar cell was manufactured in a regular production run and the process is already in the production line. â&#x20AC;&#x153;Considering that the solar cell is made on stainless steel, contains no cadmium and that the production process is an all-dry, all vacuum process where all layers (including the buffer layer) are deposited by sputtering, this achievement by our engineers is truly impressive,â&#x20AC;? said Sven LindstrĂśm, CEO Midsummer.

With the production system from Midsummer the solar cells are manufactured individually and then stringed together into modules just like crystalline solar cells. This way, lightweight ďŹ&#x201A;exible modules can easily be made in any size and shape. A dry, all-vacuum process has less stringent requirements for clean-rooms. Market shifts towards rooftop installations â&#x20AC;&#x153;The global solar cell market is facing a paradigm shift,â&#x20AC;? said Sven LindstrĂśm, CEO, Midsummer. â&#x20AC;&#x153;Fewer large solar energy parks are being built in Europe. Instead, focus is moving to installations on large buildings in cities. The lightweight and ďŹ&#x201A;exible thin ďŹ lm solar cells are ideal for this use. It is economically and environmentally more beneďŹ cial to use solar energy locally, where it is produced.â&#x20AC;?

can be made without glass. The CIGS solar modules are therefore much lighter, ďŹ&#x201A;exible and can be made frameless, to suit applications where traditional silicon solar cells cannot be used, e.g. on structures that are uneven, moving or weak.

CIGS solar cells are manufactured by sputtering the material onto 156x156 mm stainless steel substrates. The solar cells from Midsummer are free of cadmium, a toxic material usually used in CIGS and other thin ďŹ lm solar cells. Flexible CIGS solar modules are gaining market share thanks to its high efďŹ ciency, low weight, ďŹ&#x201A;exibility and durability.

Sweden-based Midsummer, a supplier of production lines for manufacturing of ďŹ&#x201A;exible thin-ďŹ lm copper indium gallium di-selenide (CIGS) solar cells, has developed a high speed process for manufacturing such cells that uses sputtering for all layers in the solar cell structure. Midsummer says it has achieved 15% active area efďŹ ciency on an entire 225cm2 solar cell using its DUO machine employing this technology

www.midsummer.se

AROUND THE WORLD

About CIGS thin ďŹ lm solar cells CIGS stands for copper-indium-gallium-selenium, a metal alloy that converts the energy of light directly into electricity by the photovoltaic effect (PV). The CIGS absorber is deposited on a stainless steel substrate, along with electrodes on the front to collect current. The cells are then connected in series and covered by a protective layer of plastic to form a ďŹ&#x201A;exible solar module.

Since a stainless steel substrate is used, the modules

BASF, Huntsman, Chinese partners adding PU capacity in Shanghai BASF SE and Huntsman Corp. as well as representatives from their China-based partners celebrated the beginning of construction on a new 240,000 metric tons per year capacity MDI polyurethane plant at the Shanghai Chemical Industry Park.

Partners in the venture â&#x20AC;&#x201C; Shanghai Hua Yi (Group) Co., Shanghai Chlor-Alkali Chemical and SINOPEC 86

AUGUST / SEPTEMBER 2014

â&#x20AC;&#x201C; expect to start production in 2017.

With the new plant, the MDI capacity at this site will be doubled to 480,000 metric tons per year and the partners plan to build a hydrogen chloride recycling plant for the production of chlorine, a precursor for MDI.

Kautex has new plant in China KAUTEX Maschinenbau has opened a new plant in China, giving the German manufacturer of blow moulding machinery an opportunity

for further growth. The previous production facility in Shunde (in Guangdong province) was already bursting at the seams. The new plant, also in Shunde, meets the current requirements in terms of production capacity and quality standards. The newly built plant will allow for the manufacturing of larger machines.

This is made possible by a higher ceiling in the production hall and correspondingly higher craneways. www.kautex-group.com www.sdkautex.com

WORLD NEWS

PVC recycling on the rise in Europe PVC recycling in Europe climbed more than 20% in 2013 according to new ďŹ gures from Recovinyl, the PVC industryâ&#x20AC;&#x2122;s recycling organization.

A total of 435,083 tons of waste PVC was recycled through Recovinyl across the groupâ&#x20AC;&#x2122;s 16 member countries. That is up from 354,173 tons in 2012.

Germany contributed 133,262 tons to the total, with the United Kingdom accounting for 88,648 tons and Spain the third largest contributor with 38,678 tons.

Potential new recycling opportunities for PVC included non-infectious medical PVC waste from hospitals, such as IV ďŹ&#x201A;uid and oxygen bags.

This type of waste is the focus of a new VinylPlus-funded research project undertaken jointly by Axion Consulting and the British Plastics Federationâ&#x20AC;&#x2122;s Vinyls Group. â&#x20AC;&#x153;We are now looking to collect and

recycle PVC from new sources, such as non-pharmacologically active waste from hospitals,â&#x20AC;? said Jane Gardner, project manager at Axion Consulting, Recovinylâ&#x20AC;&#x2122;s UK agent in Branhall, England. â&#x20AC;&#x153;Trials would be based on a successful Australian study, and we would be interested to hear from organizations looking to explore these recycling options, such as medical and care organizations,â&#x20AC;? she added.

Gardner said the latest ďŹ gures showed PVC recycling was maintaining its upward trend with demand continuing to grow for good quality recycled material that could be reused in a variety of new products.

Waste PVC-U proďŹ les comprised 50,421 tons of the UKâ&#x20AC;&#x2122;s recycling effort in 2013, with pipes, rigid and ďŹ&#x201A;exible PVC ďŹ lms and cables making up the rest.

AROUND THE WORLD Ineos to own 100% of Styrolution in BASF buyout BASF is selling its 50% share in Styrolution to Ineos, its joint venture partner in the styrenics business.

The â&#x201A;Ź1.1-billion deal is subject to the approval of shareholders and regulators. â&#x20AC;&#x153;Styrolution has fulďŹ lled its promise as a globally competitive business that competes effectively with large-scale producers from Asia and the Middle East,â&#x20AC;? said Jim Ratcliffe, chairman of Ineos Capital. â&#x20AC;&#x153;We are pleased to bring Styrolution fully into the Ineos family. â&#x20AC;&#x153;After the purchase, Styrolution will be run separately as a standalone company within Ineos, and continue to operate as it does today.â&#x20AC;?

Styrolution was founded in October 2011 as a 50-50 joint venture between BASF and Ineos.

It employs around 3200 people and has manufacturing sites in Germany, Belgium, France, Switzerland, Korea, India, Thailand, the US, Canada and Mexico.

NGR buys Dr Collin

a second skin TOKYO-based designer Satsuki Ohata has introduced a new concept inspired by cheese fondue! Fondue Slippers is a unique, mouldable footwear concept brought to life by individually dipping a foot mould in liquid PVC and setting immediately at 200-300°C. The result is a pair of fun and bendable slippers that cling to your feet like a second skin and are durable enough for both indoor and outdoor use. According to Ohata, the practical mould can be folded at the heel to be used as house slippers, or worn without the fold as shoes that can be used for running.

The project was ďŹ rst showcased at The Milano Salone Satelite exhibit; an annual observatory for young designers from around the globe. The product entered as a prototype with the promise of mass production, and Ohata has already begun planning out the next steps to bring Fondue Slippers to your home.

www.satsuki.co/fondueslipper

THE Austrian company Next Generation Recyclingmaschinen GmbH (NGR) has acquired a majority interest in the German company Dr Collin GmbH, a manufacturer of laboratory equipment, high-performance pilot systems for materials manufacturers and medical technology. With the unique and wide range of equipment available from NGR, virtually any form of plastic waste can be recycled to produce valuable plastic pellets. â&#x20AC;&#x153;If you look at the product lifecycle of plastic scrap, NGR has always been active in supporting the stages of product manufacture (i.e. production waste) and recycling. With the expertise of Collin we are expanding our capabilities in product design â&#x20AC;&#x201C; an important stage in exploiting the full potential of plastics â&#x20AC;&#x201C; and pointing the way toward effective use of ďŹ nite resources,â&#x20AC;? said Josef Hochreiter, CEO of NGR. NGR is represented by Adex Plastics Machinery. www.ngr.at AUGUST / SEPTEMBER 2014

87

BOOKS

First-ever study on global market for plastic containers CERESANA has published the first-ever study on the global market for rigid plastic containers, analyzing all relevant market data from 2005 onwards. They forecast demand for rigid plastic containers to amount to 46.2 million tons worldwide in 2021.

Demand for plastic containers differs widely depending on region and application. Expectations for future development in individual countries often vary extremely.

In the past, PET containers have been gaining a very high market share in the segments CSD and bottled water in particular.

By now, PET containers can also be found in segments such as foodstuffs, fruit juices of household chemicals. They continue to profit from their positive characteristics: They weigh comparatively little, can be recycled, do not break, and offer high clarity. At the same time, the gas barrier properties and protection against UV radiation they offer con-

tinue to improve. Apart from PET, containers made from PP are becoming more important as well. They profit from a rising demand for packaged foodstuffs in particular.

The study provides a presentation and analysis of the market for plastic containers, including forecasts up to 2021. It lists the consumption of plastic containers split by applications (in tons), revenues generated with plastic containers (in US$billion and €billion), production split by types of plastic (in tons) as well as import and export for 16 countries.

The study also offers a detailed analysis of various application areas for plastic containers, and analyses the production of containers split by the plastics PET, HDPE, PP, PS & EPS and other plastics. Profiles of the largest manufacturers of plastic containers, clearly arranged according to contact details, turnover, profit, product range, production sites, and profile summary, are also given.

www.ceresana.com/en/market-studies/packaging/plastic-containers-world

Do digital right

PVC pipe conservative study

DIGITAL is the fastest growing printing technology in the label industry, bringing with it exciting opportunities to enter new markets and take on high value projects from existing and new clients. Digital printing also provides easy ways to diversify from labels into package printing.

If you excel in digital printing it can set your business apart from your competitors and put you on a path to sustainable success. But how do you know which digital press is right for you? What substrate will deliver the best print quality?

How does digital pre-press work? How can you integrate finishing solutions? How do you sell the technology to your customers?

All these questions and more are answered in the latest edition of Mike Fairley’s Digital Label and Package Printing. No one should buy a digital press without reading this book first! A best-seller since first being published in 2009, it has been extensively updated and completely redesigned.

Digital technology is changing fast and the new edition (published in May) includes the very latest press specifications, substrate information and best practice guidelines.

The book also includes some 120 diagrams, charts, tables and images to illustrate the text.

UTAH State University’s Buried Structures Laboratory released the findings in May of a comprehensive study on PVC pipe excavations, testing and life cycle analysis entitled “PVC Pipe Longevity Report.” This 20-plus page report explores elements of PVC reliability and longevity through research on PVC pipe testing results.

The findings in this report were derived from past PVC dig-up reports and present new quality control testing results to validate the performance and longevity of PVC pipe.

Another component to the study addressed the challenge of affordability for utilities facing the process of replacing pipelines that fail.

www.amazon.com

88 AUGUST / SEPTEMBER 2014

The report can be downloaded for free at www.uni-bell.org/communication/ images/unibell_24_page_low_res1.pdf

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Seizing opportunities, overcoming barriers in Africa’s polymer markets THE ICIS African Polymers Conference will take place on 14-15 October at the Radisson Blu Sandton in Johannesburg.

Over the course of a day and a half, the international community of polymer producers, traders, distributors and buyers will convene to hear and engage with 14 strategic presentations focussing on various key challenges facing the pan-African industry. The theme of the inaugural conference is, ‘seizing opportunities and overcoming barriers in Africa’s polymer markets’.

At the time of going to print, presenters include senior representatives of the Industrial Development Corporation (IDC), Plastics│SA, MBT South Africa, Woolworths SA, Emeraude Polymers and ICIS Consulting. The event will be chaired by Jaco Smith of Carst & Walker and Delanie Bezuidenhout, CEO of the Southern African Vinyls Association (SAVA).

2. Demand sector analysis, Strategy consultancy Frost & Sullivan, 3. Africa’s regional markets, and who are pan-African knowledge partners for the event, estimate that over $1.5 trillion 4. Southern African focus.

Speakers are drawn from businesses at of investment will pour into infrastructure all stages of the plastics value chain and across Africa by 2020. This investment the industries which serve it. Reflecting – alongside a substantial upturn in many the importance of the packaging industry consumer industries – creates a significant in driving growth in polymers, this major opportunity for Africa’s plastics industry. market segment takes centre stage, As raw material suppliers to plastics although significant time is devoted to converters, the polymer industry needs identifying opportunities in construction, to be able to keep on top of market and infrastructure and recycling, as well as technical developments, both in terms spotting trends in finished- and semiof their own supply sources as well as finished product exports. demand for finished products. The ICIS The conference is expected to attract African Polymers Conference is designed close to 100 senior attendees and to bring greater clarity, transparency and delegates have already registered from independent analysis to these markets. throughout Africa, The Middle East, India, In response to the in-depth research Europe and Asia. conducted amongst potential attendees For more information and for prior to the event, the programme is registration details, visit: divided into four sections: 1. Global and regional market insights, www.icisconference.com/africanpolymers

Propak West Africa in September THE second edition of Nigeria’s largest packaging, food processing, plastics, labelling and printing trade show ‘Propak West Africa 2014’ will take place between 2–4 September at the Eko Hotel and Convention Centre in Lagos, Nigeria, organized by Montgomery West Africa.

Propak West Africa 2014 will feature international and local product leaders, regional and international experts and decision makers that are influencing and shaping West Africa’s packaging, print, plastics and labelling markets and sets itself apart at the premier Packaging trade show in West Africa.

“In 2013, the MEA market flexible packaging market totals almost $4bn. The most dynamic market is Nigeria, where flexible packaging demand has grown by around 12% over the past five years”, said PCI Films Consulting.

The Propak West Africa trade show is

Afrimold cancelled THE 2014 edition of Afrimold has been cancelled. The show was first planned for early June and then rescheduled for October, to be held in conjunction with the SA Automotive Week, but the event has now been shelved. Ron McLarty, who managed the four editions of Afrimold held to date, was clearly upset when he had to announce this. Ron and his team put a massive effort into developing the show, but the lukewarm response from mould makers and suppliers to the mould making sector resulted in the cancellation of this year’s show.

The organisers of the event, Demat of Germany, present a number of other similar shows, including Euromold, Chinamold and Amerimold, on an annual basis, is considering whether it will be feasible to hold the Afrimold show on alternate years.

supported by the Institute of Packaging Nigeria (IOPN), World Packaging Organisation (WPO), Nigeria Export Promotion Council (NEPC), Small and Medium Enterprises Development Agency of Nigeria (SMEDAN), Chartered Institute of Professional Printers of Nigeria (CIPPON) and The National Agency for Food, Drug Administration and Control (NAFDAC).

The event will also feature five seminar streams over the three days: Pro-Plas West Africa, Print Expo West Africa, FoodPro West Africa, Pro-Label West Africa and launching Digital Print Expo West Africa.

Attendees will have the opportunity to examine future trends, identify immediate long and short-term needs and uncover up and coming technologies for use in critical areas to ensure business advancement.

To register visit www.propakeastafrica.com

knowledge share and encourage networking opportunities across various industries.

• Conference registration fee is R4500 per delegate. IPSA, PACSA, IFSA, Plastics│SA members fee is R4000 per delegate. To register or for further information contact VDS Media, Jolanda van de Spreng, Tel: +27 76 424 0831,jolanda@vdsmedia.co.za

91

This event will bring industry leaders from the packaging and labelling industry, equipment and machinery suppliers, manufacturers, brand owners and retailers from the Fast Moving Consumer Goods (FMCG) sector, converters and printers to share insight into the developments of their respective value chains in the Southern African region.

This format will set the stage for extensive

AUGUST / SEPTEMBER 2014

African Label Indaba in September THE African Label & Packaging Indaba from 9-10 September at The Forum in Bryanston, Johannesburg, will offer a detailed insight into the trends and developments in the South African labelling market. This event is primarily geared at education and innovation and will focus on the main label and packaging segments of PSA, IML, shrink, wrap around and flexible packaging.

DIARY

African Polymers Conference

EVENTS ExtruAfrica

5-8 Aug

Interplast Brasil Interbuild

18-22 Aug 20-23 Aug

SAPPMA Pipes V111 Conference Propak West Africa African Label & Packaging Indaba Agricultural Film 2014

2 Sept

SPE Thermoforming Conference Electra Mining

OLEDs World Summit International Coastal Cleanup Day Polyurethanes Technical Conference WindEnergy Hamburg Iran Plast Global Plastics Summit Interplas (UK)

2-4 Sept 9 Sept

Pilansberg, NorthWest Joinville, SC, Brazil Nasrec, Johannesburg Bytes Conference Centre, Midrand Eko Hotel & Suites, Lagos, Nigeria Johannesburg

15-17 Sept Crowne Plaza Barcelona Fira Center, Spain 15-18 Sept Schaumburg, Illinois, USA

www.extruafrica.org.za

Barrier Pharma Packaging

14-15 Oct

Princeton, New Jersey, USA

www.amiplastics.co.za

www.messebrasil.com.br www.interbuild.co.za

14-15 Oct

Johannesburg

www.icisconference.com

www.sappma.co.za

ICIS African Polymers Conference Fakuma

14-18 Oct

Friederichshafen, Germany

www.fakuma-messe.de

www.propakwestafrica.com

Propak Cape

21-23 Oct

www.propakcape.co.za

www.vdsmedia.co.za

Global Vinyls Council

21-23 Oct

Cape Town Int’l Convention Centre Hilton Hotel, Sandton, Johannesburg

Materialica 2014 Vinyl 2014

21-23 Oct 22 Oct

www.materialica.de www.savinyls.co.za

Wood Plastic Composites 2014

3-5 Nov

Munich, Germany Hilton, Johannesburg Vienna, Austria

PETnology

10-11 Nov

Nuremberg, Germany

www.petnology.com

Emballage

17-20 Nov

Paris Nord Villpepinte, France

www.all4pack.com

Euromold

25-28 Nov

Frankfurt, Germany www.euromold.com

Fire Resistance 2014

9-11 Dec

Cologne, Germany

Arabplast 2015

10-13 Jan

Dubai Int’l www.arabplast.info Convention Centre, UAE

PlastIndia 2015

5-10 Feb

Pragati Maidan, New Delhi, India

www.plastindia.org

NPE 2015

23-27 Mar

Orlando, Florida, USA

www.npe.org

Plast 2015

5-9 May

Fiera Milano, Italy

ChinaPlas 2015

20-23 May Guangzhou, PR China

www.amiplastics.com/ events www.thermoformingdivision. com

15-19 Sept Expo Centre, www.electramining.co.za Nasrec, Johannesburg 16-18 Sept Berkeley, California, www.oledsworldsummit.

USA com 20 Sept entire coast of SA

www.savinyls.co.za

www.amiconferences.com

www.amiplastics.com

22-24 Sept Dallas, Texas, USA www.mericanchemistry.com

23-26 Sept Hamburg Messe, Germany 25-29 Sept Tehran, Iran 30 Sept-2 Chicago, Illinois, Oct USA 30 Sept-2 Birmingham, Oct England International AVK 6-7 Oct CCD Congress Conference Center Düsseldorf Composites 7-9 Oct Messe Düsseldorf, Europe Germany Plastics Electronic 7-9 Oct Grenoble, France CAMX 13-16 Oct Orlando, Florida, (Composites USA & Advanced Materials Expo)

2015 www. windenergyhamburg.com www.iranplast.com www.GlobalPlasticsSummit. com www.interplasuk.com www.avk-tv.de www.composites-europe. com www.plastic-electronics.org www.thecamx.org

www.plastonline.org www.ChinaplasOnline.com

KZN Industrial 9-12 Jun Technology Show

Durban Exhibition Centre

CAMX (Composites & Advanced Materials)

Dallas, Texas, USA www.thecamx.org

26-29 Oct

www.kznindustrial.co.za

COMING UP PISA CONFERENCE AT SA AUTOMOTIVE WEEK SA AUTOMOTIVE Week is to run from 13-17 October at Gallagher Estate in Midrand. Presented every two years, the Auto Week is Africa’s automotive intellectual gathering and focuses on stimulating trade and partnership opportunities in the manufacturing and related sectors.

A seminar titled Manufacturing Tooling Innovations is to be presented by PISA (Plastics Institute of Southern Africa) on Wednesday 15 October at which a range of speakers, including presenters from the Fraunhofer Institute for Machine Tools and Aachen University of Applied Sciences, will provide a view on European best practise, highlighting recent successes. www.saaw.co.za

THERMOFORMING SHOW IN USA THE Society of Plastics Engineers in the USA is to 92 92 AUGUST AUGUST/ /SEPTEMBER SEPTEMBER2014 2014

present its SPE Thermoforming Conference from 15-18 September in Schaumburg, Illinois, USA. Parts entered in the accompanying design competition will be on display during this 23rd edition of the event, at the Renaissance Hotel in Schaumburg, Illinois. www.thermoformingdivision.com

INTERNATIONAL COASTAL CLEANUP ON SATURDAY 20 SEPTEMBER THIS year will see South Africa’s 19th International Coastal Clean-up taking place on Saturday 20 September. The International Coastal Clean-up is the world’s largest volunteer effort to clean up waterways and the ocean. If you would like to help please contact John Kieser at john.kieser@plasticssa.co.za

WINDENERGY HAMBURG WINDEnergy Hamburg, the leading international fair for the wind industry, will be held from 23-26

September. The expo covers the whole of the value chain, both onshore and offshore. More than 1,000 exhibitors from all over the world are expected. The main focus of the expo will be the energy transition in Germany as the leading technology location, and above all the key role of wind energy in its realisation. The expo will also showcase current and future technology developments, showing how they contribute to innovative solutions for sustainable energy supply. www.windenergyhamburg.com

COMPOSITES EUROPE 2014 COMPOSITES Europe in Düsseldorf from 7–9 October will once again showcase the full range of fibre-reinforced plastics. More than 400 exhibitors from 25 nations are expected to present new lightweight construction concepts, materials, and the latest production and automation solutions. A total of 10,000 lightweight construction experts representing automotive engineering, aviation and boatbuilding as

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Application development plus collective ingenuity fuel innovation healthcare sectors.

It is emphasising how advances in the design stage enable customers to more accurately predict how DuPont materials will perform, based on enhancements made

by DuPont Engineering Research to its materials modelling expertise.

“Our state-of-the-art advanced computer modelling and simulation will help original equipment manufacturers confidently select the best material for the application because they will better understand how the material will perform given the

Next step for FreeFormer at Fakuma Arburg will present the next step in its Allrounder ‘Freeformer’ production efficiency strategy at Fakuma (14-18 October in Friedrichshafen, Germany). Arburg is now the only injection machine maker to cover the entire spectrum from additive manufacturing to injection moulding, from one-off parts to mass-produced items. A total of 11 exhibits on the exhibition stand will present innovative applications, special industrial and automation solutions as well as practical examples

www.arburg.com

Modelling expertise – DuPont is to show how its CAE and Predictive Engineering Solutions technologies can predict how its materials will perform in active use, in this case a DuPont Zytel® PA612 long chain polyamide and glass reinforced Zytel® PA66 are simulated in automotive automotive coolant pipes Zytel®

dynamics of their particular product,” said Craig Norrey, head of design (EMEA) at DuPont.

MEDTEC-Automatica clear joining USING laser technology to weld plastics brings many economic and technological benefits, and has already established itself in many industrial sectors. LPKF Laser & Electronics AG is to present laser welding systems at MEDTEC Europe in Stuttgart from 3-5 June.

The benefits of laser plastic welding are best highlighted by medical technology applications: the method is particularly hygienic, particlefree and safe. LPKF will be showcasing its PrecisionWeld technology, a highly precise system specially designed for welding fine microfluidic channels and clear-clear joints. The recently developed ‘Clear Joining’ laser process enables transparent plastics to be welded without using any additives

www.lpkf-laserwelding.com

well as the wind energy and construction sectors are expected at the Düsseldorf Exhibition Centre. www.composites-europe.com

NEW TECHNOLOGIES FOR AEROSPACE INDUSTRY THE 9th AIRTEC takes place from 28–30 October at the Exhibition Centre Frankfurt, Germany.

During three days, up to 500 exhibitors from 30 nations representing the whole supply chain of the aerospace industry will be showing their products and services to an international specialised audience from 45 nations. Amongst them, many market leaders and numerous SMEs from Europe, the United States and Asia will be represented. The most important product fields are design, engineering, materials (composites, metals, ceramic), production, electronics, sensors, testing, avionics, components, systems and life cycle support. www.airtec.aero

WOOD PLASTIC COMPOSITES CONFERENCE CELEBRATES 10 YEARS THE 10th edition of the Wood Plastics Composites conference will take place from 3-5 November at the Austria Trend Hotel Savoyen in Vienna, Austria. The conference will include presentations from the Chinese WoodPlastic Professional Committee, Holzforschung Austria, WPC Corporation of Japan, German producer Rehau and Fiberon of North America.

The programme will also include a session on decoration & appearance with papers from Wöhler Brush Tech GmbH, Shepherd Color and Q-Lab Corp. www.amiconferences.com

EUROMOLD 2014 ESTABLISHES NEW DIRECTIONS IN GLOBAL ENGINEERING EUROMOLD 2014 is being held from 25-28 November at the Frankfurt am Main Exhibition

Centre. Following 58,673 visitors from 83 countries and 1,056 exhibitors from 37 countries in 2013, EuroMold 2014 is striving to set new records. www.euromold.com

FIRE RESISTANCE 2014 THE 9th edition of AMI’s Fire Resistance in Plastics 2014 conference will take place from 9-11 December at the Maritim Hotel in Cologne, Germany. This yearly event attracts an ever-growing number of participants, who come to learn about the latest developments in flame retardancy and flame retardant plastics. For the first time, the audience will be able to hear a utility company’s view of plastics in the power industry with a keynote presentation from UK energy provider RWE Npower. www.euromold.com AUGUST / SEPTEMBER 2014

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www.dupont.com

DUPONT group will be one of the leading exhibitors at Fakuma at the Friedrichshafen Exhibition Centre on Lake Constance from 14-18 October. Close to 1300 exhibitors are expected – 1288 to be exact – at this popular event, which is recognised as a global forum for the injection moulding sector as well as its related technologies.

DuPont will present its Computer Aided Engineering (CAE) and Predictive Engineering Solutions coupled with its broad portfolio of advanced materials for the automotive, electronics and

Over 1000 exhibitors register for Plast 2015 EBLOW and HYBLOW series stand out in packaging sector PLAST 2015 will take place on 5-9 May 2015 at the Fiera Milano fairgrounds in Rho, during the EXPO 2015 inaugural week. Already there are more than 1,000 companies who have cast their hats into the ring, affirming a strong interest in this international fair, the most important European event for the industry to take place in 2015.

In spite of the economic crisis and recession that have struck almost all branches of Italian and international industry, the plastics sector has affirmed its solidity, having already reached, almost one year prior to the opening of the doors, the same number of registered exhibitors as in the 2012 edition for the equivalent period.

“The plastics and rubber machinery and moulds sector has held firm in a contest of continuing domestic recession,” stated the Promaplast managing director Mario Maggiani. “It is a sector of excellence in Italy which has made innovation its strong suit. The 2012 edition of PLAST had a total of 1,500 exhibitors and 50,000 visitors. In 2015, thanks to the concomitance with the opening week of EXPO, we expect an even stronger response from exhibitors and visitors alike.”

One of the entrances at the show grounds in Milan at the last edition of the Italian event, Plast 2012

www.plastonline.org

Extra hall opened for Propak Cape 2014

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Innovative packaging technology expected at October show DUE to the high demand for exhibitor space, an additional hall has been opened up for exhibitors at Propak Cape (21-23 October).

Halls 1,2 and 3 at the Cape Town International Convention Centre, which have been used for the triennial Cape Show since it moved to the CTICC in the 1990s, have been sold out, resulting in the opening up of halls 4 a+b for the first time ever in the history of Propak Cape.

The show’s focus is packaging, food processing, plastics, printing, labelling and wine manufacturing equipment.

TOP local and international companies in packaging, food processing, printing, labelling and plastics will showcase the newest products, latest industry trends and product developments.

Together with the co-located shows FoodPro, Pro-Plas Expo, Pro-Label Cape 94

AUGUST / SEPTEMBER 2014

and Print Expo, Propak Cape will bring exhibitors together across the various sectors and enable visitors to engage with the most progressive companies in the country.

One such company is international supplier of adhesive systems, Robatech.

They will use the event to exhibit the latest developments in Hotmelt application technology for the packaging, printing, paper and plastics industries.

The latest Hotmelt system will be on display with its new touch screen technology and production support software, making it an integral part of production reporting, able to reduce production costs and down time. The company will also be launching other new products at the event.

Spray technology is used in many aspects of food packaging, including

food preparation prior to packaging for mould prevention, washing, sterilising and packaging prior to filling, inserting product into containers, sealing, applying adhesives for label application, spraying protective agents on packages for transport and more. As a result, Monitor Engineering will be exhibiting its extensive line of spray nozzles and systems designed specifically to help maintain packaging content quality, minimise waste and increase efficiency.

Supplier of printed and laminated flexible packaging materials, Positive Packaging Industries will be showcasing its international product range to the South African packaging industry. The company’s product range includes flexible packaging materials, cylinders, different types of films as well as shrink sleeves and labels. www.propakcape.co.za

CLASSIFIED ADVERTS

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If you’d like to subscribe, email your details to saplastics@iafrica.com or visit our website at www.saplastics.co.za

Advertisers: Aug / Sept 2014 ACD RotoFlo 41 Adex (Gamma Meccanica) 75 Alfa Gama 45 Ampacet 11 Annecat Plastics 65 BASF 61 Carst & Walker 15 DemaPlastech 69 DH Polymers 47 Hosaf 55 ICIS 46 Jenowill 03 Karbochem 79 Mangwanani Spa 26 Masterbatch SA 29 MGMW Trading 90 Miracle Mould 42, 43 Mitsubishi Electric Europe 51 MJH Machine Tools 21 Nissei ASB 49 Orion Engineered Carbons 20 Performance Colour Systems 23 Pioneer Plastics 37 PlastiChem IFC PlasticsSA 01 Plasti-Weld 73 Plastomark 31 POLYCO 17 Polysaf Chemical 67 Propak Cape 93 Protea Polymers IBC Rawmac 71 Relloy 13,77 REPI S.p.A. 81 Safripol 05 SAPY Colours 63 SES 85 Victor Fortune OBC Welltec 89 West African Group 24, 25 Your Technical Solutions 39

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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: ‘Cartonplast’ (twinwall/hollow profile sheet); Multilayer sheet for packaging; Semi-foamed sheet for thermoforming MATERIALS FOR THERMOFORMED PACKAGING Sealing films for trays and top web for FFS machines PET/PE laminated sheet for FFS packaging lines; OPS, PP, PET sheet for general packaging; PP/EVOH/PP for high barrier containers

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Sheets made of the polycarbonate Makrolon® from Bayer are installed over an area of 7500m² on the inner ring of the stadium roof

Beautiful and functional

SPORTS

Special material for stadiums in Brazil THE weather in Brasilia is wildly erratic.

Scorching heat, then heavy rain. The 70,000 spectators at the new Estádio Nacional, one of the venues for this year’s soccer World Cup, had to be protected against both. The solution is an extraordinary roof structure that is every bit as beautiful as it is functional. Sheets of a transparent, high-performance plastic from Bayer MaterialScience fend off the rain and the sun’s rays.

These sheets, each 10 metres long, cover some 7,500m2 of the roof’s inner ring. They have a coating that repels ultraviolet rays while at the same time letting through enough light so the grass on the field can thrive. The circular suspension roof is not just extremely functional, it is also another architectural accent in the Brazilian capital, which has been declared a World Heritage Site in recognition of its numerous exceptional structures.

Another architectural highlight is the “Arena das Dunas” (Stadium of the Dunes) in the coastal city of Natal. Here, the spaces in the roof structure are filled with 20 high, slim elements made of Bayer’s transparent polycarbonate of which none resembles another. www.materialscience.bayer 96 AUGUST / SEPTEMBER 2014

The stadiums in Brazil are just two of many sports venues around the world where creative concepts and unique structures have been made possible with the help of polycarbonate.

From the shimmering, honey-coloured ‘Amber Arena’ in Gdansk, Poland, built for the 2012 European Soccer Championship, to the ‘Spyridon Louis’ Olympic stadium in Athens, Greece

The ‘Arena das Dunas’ (Stadium of the Dunes) in the coastal city of Natal in Brazil

PIPE

COMMODITIES (HD/LL/LD)

ADDITIVES

ENGINEERING

ELASTOMERS

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

“more than just a chemical supplier”

Johannesburg: +27 (0) 11 821 842 3300 3600 Durban: +27 (0) 31 450 5777 Port Elizabeth: +27 (0) 41 401 5500 Town: Cape Town: +27 (0) 21 550 8232 www.proteachemicals.co.za

Fax: +27 (0) 11 821 842-3700 3446